Contra-rotating turbine flow sensor with integrated structure

Abstract

The invention relates to the technical field of instruments and meters, in particular to a contra-rotating turbine flow sensor of an integrated structure. The shaft system part comprises an upstream flow guide plate, a transmission shaft, a conical flow guide part, an upstream turbine, a middle transition flow guide part, a downstream turbine, a downstream transition flow guide part, a downstream flow guide plate and a locking nut, and one end of the transmission shaft is connected to the upstream flow guide plate; the conical flow guide part, the upstream turbine, the middle transition flow guide part, the downstream turbine, the downstream transition flow guide part, the downstream flow guide plate and the locking nut are sequentially arranged on the transmission shaft in a sleeving mode, and the shafting part is axially locked and embedded in the shell by fastening the locking nut. An electrical assembly. According to the invention, the structure is compact, the installation adaptability is good, the pressure loss is obviously reduced, the energy-saving effect is obvious, the wide range, the high precision and the strong medium adaptability are improved, the reliability is high, the signal synchronism and the anti-interference capability are strong, the production process is simplified, and the comprehensive cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of instrumentation, and more particularly to an integrated counter-rotating turbine flow sensor. Background Technology

[0002] Turbine flow meters are velocity-type flow measurement instruments widely used in industrial process control, energy metering, and fluid monitoring. They calculate flow rate by detecting the frequency of the fluid-driven turbine rotation, offering advantages such as high measurement accuracy, fast response, and relatively simple structure. Traditional turbine flow meters typically employ a single turbine structure, where fluid flows through a single turbine rotor. The turbine's rotational speed is proportional to the flow velocity, and the turbine speed is detected and converted into a flow signal using magnetoelectric, photoelectric, or other sensors.

[0003] With the increasing demands of industrial measurement, especially in scenarios requiring wide measurement range, multi-media adaptability, and high reliability, single-turbine flow meters are gradually revealing some inherent limitations: First, their measurement range is significantly affected by factors such as turbine bearing friction and fluid viscosity changes, and they are prone to sensitivity degradation or even failure to start in low-velocity or high-viscosity media; second, the single-turbine structure is highly sensitive to fluid velocity distribution, requiring relatively long straight pipe sections before and after it to ensure a fully developed flow pattern, which limits its application in space-constrained environments; furthermore, since it relies on only a single sensor signal, the entire measurement system will completely fail if the turbine jams or the sensor fails, and its reliability needs to be improved.

[0004] To overcome the aforementioned problems, the industry has successively proposed the concept of counter-rotating turbine flow meters. This involves arranging two turbines with different characteristics (e.g., turbines with different blade angles or materials) in the flow channel, and using the difference in rotational speed between the two turbines to compensate for viscosity changes, expand the range ratio, or achieve self-diagnostic functions. However, existing counter-rotating turbine flow meters mostly adopt a split or series structure. The two turbines are usually installed independently in different measurement sections or connected through complex transmission mechanisms, resulting in a bulky overall structure, increased size, higher pressure loss, and increased difficulty in mechanical assembly and calibration. Furthermore, split designs often require two independent signal detection and processing units, increasing system costs and making signal synchronization and integration more complex.

[0005] Furthermore, existing counter-rotating turbine flow meters largely rely on separately acquiring pulse signals from each of the two turbines for signal processing and then performing external calculations. This fails to fully utilize the advantages of integrated acquisition and real-time correlation analysis, resulting in lag in dynamic response and susceptibility to misjudgment due to signal interference under conditions of strong vibration and high levels of impurities. Therefore, how to achieve a highly compact dual-turbine structure, integrated signal acquisition, and intelligent fault diagnosis without significantly increasing pressure loss and space occupation has become a pressing technical problem to be solved in the field of turbine flow meters.

[0006] In summary, providing an integrated counter-rotating turbine flow meter that is compact, highly reliable, and adaptable to a wide range of fluid operating conditions is of great significance for improving the overall performance and applicability of flow measurement. Summary of the Invention

[0007] To address the technical problems existing in the prior art, embodiments of the present invention provide an integrated counter-rotating turbine flow sensor. The technical solution is as follows: An integrated counter-rotating turbine flow sensor includes: Housing components provide airflow guidance and support; A shaft system is disposed within the housing component. The shaft system includes an upstream guide plate, a drive shaft, a tapered guide plate, an upstream turbine, an intermediate transition guide plate, a downstream turbine, a downstream transition guide plate, a downstream guide plate, and a locking nut. One end of the drive shaft is connected to the upstream guide plate. The tapered guide plate, the upstream turbine, the intermediate transition guide plate, the downstream turbine, the downstream transition guide plate, the downstream guide plate, and the locking nut are sequentially mounted on the drive shaft. The shaft system is axially locked and embedded within the housing component by tightening the locking nut. An electrical component, disposed on the housing, is used to monitor the rotational speed of the shaft component propelled by fluid within the housing to determine the flow rate through the counter-rotating turbine flow sensor.

[0008] Preferably, the housing component includes a housing base and a housing cover, the housing base being used to mount the shaft system and the electrical components, and the housing cover providing protection for the electrical components on the housing base.

[0009] Preferably, the housing base includes a flow channel and a mounting platform. The flow channel is used to mount the shaft component, allowing liquid to flow through and drive the shaft component to rotate. The mounting platform is used on the flow channel to mount the electrical components and to detect the rotational speed of the shaft component and analyze the liquid flow rate.

[0010] Preferably, both ends of the inner wall of the flow channel are machined with bosses for mounting the shaft components; the mounting platform is provided with mounting holes for a speed sensor, a temperature sensor, a circuit board, and a housing cover for mounting the electrical components.

[0011] Preferably, the housing cover is provided with a square platform, and the housing cover is sealed and installed on the mounting platform by screws passing through the square platform.

[0012] Preferably, the drive shaft is screwed into a threaded hole at one end of the upstream guide plate via an external thread at one end; the upstream turbine is rotatably mounted on the drive shaft via an embedded bearing; the downstream turbine has the same structure as the upstream turbine, and the downstream turbine is rotatably mounted on the drive shaft via an embedded bearing.

[0013] Preferably, the electrical components include a sensor, a flow transmitter, and an electrical connector. The sensor is mounted on the mounting platform to monitor the rotational speed of the shaft components and the liquid temperature in the flow channel. The flow transmitter is mounted on the mounting platform and electrically connected to the sensor to receive and process the sensor signals, and then transmits the data externally through the electrical connector mounted on the housing cover.

[0014] Preferably, the sensor includes a speed sensor and a temperature sensor, the speed sensor is installed in the speed sensor mounting hole, the temperature sensor is installed in the temperature sensor mounting hole, and both the speed sensor and the temperature sensor are electrically connected to the flow transmitter.

[0015] Preferably, the flow transmitter includes a signal processing element, a flow calculation element, and a storage element. The signal processing element is disposed on the mounting platform, the flow calculation element is disposed on the signal processing element, and the storage element is disposed on the flow calculation element. These elements are respectively used to receive and process the rotational speed signal and temperature signal transmitted by the sensor, and to perform flow calculation using the rotational speed signal and temperature signal based on a built-in flow calculation algorithm. The transmitter stores the physical property database, algorithm formula parameters, and calculated flow data required by the flow calculation algorithm, and finally transmits the flow signal through the connected electrical connector. The flow transmitter also has a real-time self-diagnostic algorithm based on the correlation between the two turbine rotational speeds.

[0016] Preferably, the signal processing element is mounted on the mounting platform via a first circuit fixing bracket embedded thereon, the flow calculation element is mounted on the signal processing element via a second circuit fixing bracket embedded thereon, and the storage element is mounted on the flow calculation element via a circuit fixing bolt embedded thereon; the signal processing element, the flow calculation element, and the storage element are electrically connected via a flexible circuit board.

[0017] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: (1) The integrated counter-rotating turbine flow sensor of the present invention has a compact structure, good installation adaptability, significantly reduces pressure loss, has obvious energy-saving effect, improves wide range, high precision and strong media adaptability, high reliability, strong signal synchronization and anti-interference ability, simplifies the production process and reduces the overall cost. (2) The integrated counter-rotating turbine flow sensor of the present invention integrates the shaft system into an integral housing optimized by fluid dynamics, completely eliminating the complex connection structure of the split type, greatly reducing the overall axial length and volume of the flow meter, reducing the requirements for external installation straight pipe sections, making it flexible to be applied to industrial sites with limited space, and broadening the application scenarios; through the optimized streamlined integrated flow channel design, combined with the coaxial, low-resistance dual turbine layout, the fluid flow is smoother, avoiding the eddy current and throttling effect brought by the internal cavity, effectively reducing the permanent pressure loss during the operation of the flow meter, and saving pumping energy consumption for pipeline systems that need to operate continuously for a long time (such as water supply and oil pipeline networks), bringing long-term operational economic benefits; (3) The dual-turbine flow sensor of the present invention has an integrated structure. Under normal operating conditions, the speed ratio or speed difference of the two turbines is maintained within a certain empirical / theoretical range. Once a single turbine blade is damaged, the bearing is abnormally stuck, the sensor fails locally, or there are abnormally large particles of impurities entangled in the fluid, the correlation signal between the two will show a characteristic deviation. The system can immediately trigger an alarm and can switch to the mode supported by the healthy turbine according to the preset strategy to provide degraded but still reliable flow data. This avoids the risk of "one loss and all stop" of the traditional single-sensor flow meter and greatly improves the reliability and maintainability of the measurement system. In addition, the dual-turbine design makes its response characteristics to fluid velocity and viscosity different. By analyzing the speed signals of the two turbines in real time through the microprocessor, the influence of fluid viscosity and temperature changes on the measurement can be dynamically compensated. This allows the present invention to maintain high sensitivity and accuracy when measuring low-velocity and high-viscosity fluids, while maintaining stable performance in the high-velocity range. This achieves a wide range ratio and accurate measurement across the entire range that far exceeds that of a single-turbine flow meter. (4) The integrated counter-rotating turbine flow sensor of the present invention, since the two turbines are coaxial and arranged close to each other, their rotational speed signals are synchronously collected by the two integrated rotational speed sensors in the same electromagnetic environment, which fundamentally eliminates the errors and noise introduced by the asynchronous installation position, transmission line or sampling time of the split dual sensor, improves the correlation and signal-to-noise ratio of the signal, and lays a solid foundation for subsequent accurate correlation analysis and diagnosis. The integrated structure reduces the number of parts and assembly links, reduces the difficulty and cost of machining, assembly and sealing, and also reduces the need for external wiring and independent signal processing due to the integrated design of electrical components. This not only reduces the manufacturing cost of a single product, but also improves production efficiency and product consistency, thereby enhancing the overall market competitiveness of the product. Attached Figure Description

[0018] Figure 1 This is a front view of the integrated counter-rotating turbine flow sensor of the present invention; Figure 2 This is a longitudinal sectional front view of the integrated counter-rotating turbine flow sensor of the present invention; Figure 3 This is a front cross-sectional view of the integrated counter-rotating turbine flow sensor of the present invention. Figure 4 This is a front view of the shaft system components in the integrated counter-rotating turbine flow sensor of the present invention; Figure 5 This is a longitudinal sectional front view of the shaft system component in the integrated counter-rotating turbine flow sensor of the present invention; Figure 6 This is a three-dimensional structural diagram of the housing base in the integrated counter-rotating turbine flow sensor of the present invention; Figure 7 This is a three-dimensional structural diagram of the housing cover in the integrated counter-rotating turbine flow sensor of the present invention; Figure 8 This is a schematic diagram showing the connection between the housing base, housing cover, and electrical connector in the integrated counter-rotating turbine flow sensor of the present invention. Figure 9 This is a schematic diagram of the process of installing shaft components on the housing base in the integrated counter-rotating turbine flow sensor of the present invention; Figure 10 This is a schematic diagram illustrating the process of installing signal processing elements on the housing base of the integrated counter-rotating turbine flow sensor of the present invention. Figure 11 This is a schematic diagram of the flow transmitter mounted on the housing base in the integrated counter-rotating turbine flow sensor of the present invention. Figure 12 This is a schematic diagram of the potting process for the integrated counter-rotating turbine flow sensor of the present invention. Figure 13 This is a schematic diagram of the electrical connector installed in the integrated counter-rotating turbine flow sensor of the present invention.

[0019] In the diagram: 1-Shell cover, 2-Flow channel, 3-Mounting platform, 4-Speed ​​sensor mounting hole, 5-Temperature sensor mounting hole, 6-Circuit board mounting hole, 7-Shell cover mounting hole, 8-Square platform, 9-First mounting through hole, 10-Screw, 12-Second mounting through hole, 13-Third mounting through hole, 14-Upstream guide plate, 15-Drive shaft, 16-Conical guide, 17-Upstream turbine, 18-Intermediate transition guide, 19-Downstream turbine, 20-Downstream transition guide, 21-Downstream guide plate. 22-Locking nut, 23-Bearing, 24-Bearing washer, 26-Electrical connector, 27-Speed ​​sensor, 28-Temperature sensor, 29-Signal processing element, 30-Flow calculation element, 31-Storage element, 32-First circuit mounting bracket, 33-Second circuit mounting bracket, 34-Circuit mounting bolt, 35-Flexible circuit board, 36-Fixing bolt, 37-Potting tool, 38-Indicated area, 39-Insulating gasket, 40-Shaft component, 41-Aerospace fastener fuse hole, 42-Boss. Detailed Implementation

[0020] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0021] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0022] In the embodiments of this invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning. Similarly, the terms "of," "corresponding (relevant)," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning.

[0023] In this embodiment of the invention, sometimes a subscript such as W1 may be written in a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0024] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0025] according to Figures 1-12As shown, an integrated counter-rotating turbine flow sensor includes a housing, a shaft system, and an electrical assembly. The shaft system is rotated on the housing by a flowing liquid. The electrical assembly is disposed on the housing and is used to detect the rotational speed of the shaft system in order to analyze the flow rate through the shaft system.

[0026] The housing component includes a housing base and a housing cover 1. The housing base is used to mount the shaft assembly and the electrical components, and the housing cover 1 provides protection for the electrical components on the housing base. The housing base includes a flow channel 2 and a mounting platform 3. The flow channel 2 is used to mount the shaft assembly, allowing liquid to flow through and drive the shaft assembly to rotate. The mounting platform 3 is used on the flow channel 2 to mount the electrical components and to detect the rotational speed of the shaft assembly and analyze the liquid flow rate.

[0027] The flow channel 2 is tubular in shape, with mechanical interfaces at both ends. These mechanical interfaces are standard aviation interfaces and are machined with aviation fastener fuse holes 41. Bosses 42 are machined at both ends of the inner wall of the flow channel 2 for mounting the shaft components.

[0028] The mounting platform 3 is provided with speed sensor mounting holes 4, temperature sensor mounting holes 5, circuit board mounting holes 6, and housing cover mounting holes 7 for mounting the electrical components. Further, there are two speed sensor mounting holes 4, distributed longitudinally along the flow channel 2, for detecting the rotational speed of the shaft components. There are three circuit board mounting holes 6, distributed circumferentially. There are four housing cover mounting holes 7, distributed one at each of the four corners of the mounting platform 3. Alternatively, the mounting platform 3 and the flow channel 2 are integrally machined.

[0029] The outer casing 1 is cylindrical in shape, and a square platform 8 is provided on the opening of the outer casing 1. The square platform 8 has the same dimensions and shape as the mounting platform 3. Four first mounting through holes 9 are provided on the square platform 8, and these four holes are distributed one-to-one at the four corners of the square platform 8, corresponding one-to-one with the four mounting holes 7 of the outer casing. By passing a screw 10 through the first mounting through hole 9, the external thread of the screw 10 engages with the internal thread in the mounting hole 7 of the outer casing, thereby mounting the outer casing 1 onto the mounting platform 3. The four screws 10 are screwed one-to-one into the four mounting holes 7 of the outer casing. Furthermore, a gasket is provided between the square platform 8 and the mounting platform 3 to improve the sealing between them.

[0030] The bottom surface of the outer casing 1 is provided with a second mounting through hole 12 and a third mounting through hole 13. There are four second mounting through holes 12, evenly distributed circumferentially. The third mounting through hole 13 is located at the center of the bottom surface of the outer casing 1. Both the second mounting through hole 12 and the third mounting through hole 13 are used to mount the electrical components.

[0031] The shaft system includes an upstream guide plate 14, a drive shaft 15, a tapered guide 16, an upstream turbine 17, an intermediate transition guide 18, a downstream turbine 19, a downstream transition guide 20, and a downstream guide plate 21. One end of the drive shaft 15 is mounted on the upstream guide plate 14. The tapered guide 16, the upstream turbine 17, the intermediate transition guide 18, the downstream turbine 19, the downstream transition guide 20, and the downstream guide plate 21 are sequentially mounted on the drive shaft 15, and the drive shaft 15 is axially locked by a locking nut 22 fastened to the other end.

[0032] Both ends of the drive shaft 15 are provided with external threads, and the drive shaft 15 is screwed into the threaded hole at one end of the upstream guide plate 14 through the external thread on one end. The upstream turbine 17 is fitted with a bearing 23, and the upstream turbine 17 is rotatably mounted on the drive shaft 15 via the bearing 23. Furthermore, two bearings 23 are provided, axially spaced apart within the upstream turbine 17, and a bearing washer 24 is provided between the two bearings 23. The downstream turbine 19 has the same structure as the upstream turbine 17, and the downstream turbine 19 is rotatably mounted on the drive shaft 15 via its internal bearing 23. Alternatively, the rotation direction of the downstream turbine 19 is opposite to that of the upstream turbine 17.

[0033] The method for embedding the shaft components within the flow channel is as follows: S1: Remove the locking nut 22 and the downstream guide plate 21 from the other end of the drive shaft 15; S2: Insert the other end of the drive shaft 15, which is fitted with the conical guide 16, the upstream turbine 17, the intermediate transition guide 18, the downstream turbine 19 and the downstream transition guide 20, from one end of the flow channel 2, so that the tail of the upstream guide plate 14 abuts against the boss 42 at one end of the flow channel 2. S3: Insert the downstream guide plate 21 from the other end of the flow channel 2, and mount the downstream guide plate 21 on the other end of the drive shaft 15; S4: Tighten the locking nut 22 onto the external thread at the other end of the drive shaft 15, so that the tail end of the downstream guide plate 21 is tightly pressed against the boss 42 at the other end of the flow channel 2, and the installation of the shaft system in the flow channel 2 is completed.

[0034] It should be noted that the upstream turbine 17 and the downstream turbine 19 are core components of the flow meter shaft system. Under the scouring of the fluid flowing through the flow channel 2, the upstream turbine 17 and the downstream turbine 19 begin to rotate. The turbine rotation speed is proportional to the volumetric flow rate of the fluid passing through the flow channel 2 at this time. By measuring the turbine rotation speed and further processing the rotation speed signal, the volumetric flow rate information at this time can be obtained.

[0035] The electrical components include a sensor, a flow transmitter, and an electrical connector 26. The sensor is mounted on the mounting platform 3 and is used to monitor the rotational speed of the shaft components and the liquid temperature in the flow channel 2. The flow transmitter is mounted on the mounting platform 3 and is electrically connected to the sensor to receive and process the sensor signals, and then transmits the data to the outside through the electrical connector 26 mounted on the housing cover 1.

[0036] The sensor includes a speed sensor 27 and a temperature sensor 28. The speed sensor 27 is installed in the speed sensor mounting hole 4, and the temperature sensor 28 is installed in the temperature sensor mounting hole 5. Both the speed sensor 27 and the temperature sensor 28 are electrically connected to the flow transmitter.

[0037] Two speed sensors 27 are provided, and each speed sensor 27 is installed in one of the two speed sensor mounting holes 4. The speed sensors 27 and the temperature sensor 28 are fixed to the speed sensor mounting holes 4 and the temperature sensor mounting holes 5 by adhesive. After the sensors are installed, glue is poured into the mounting holes to fill the gaps and fix the sensor body to prevent loosening. In addition, pouring glue into the mounting holes also serves to seal, insulate, and prevent corrosion, which is beneficial to the normal operation of the sensors. Alternatively, the speed sensor 27 can be a Hall effect speed sensor, a magnetoelectric speed sensor, or an eddy current speed sensor.

[0038] The flow transmitter includes a signal processing element 29, a flow calculation element 30, and a storage element 31. The signal processing element 29 is mounted on the mounting platform 3, the flow calculation element 30 is mounted on the signal processing element 29, and the storage element 31 is mounted on the flow calculation element 30. These elements are used to receive and process the rotation speed signal and temperature signal transmitted by the sensor, respectively, and to perform flow calculation using the rotation speed signal and temperature signal based on the built-in flow calculation algorithm. The device stores the physical property database, algorithm formula parameters, and calculated flow data required by the flow calculation algorithm, and finally transmits the flow signal through the connected electrical connector 26.

[0039] The signal processing element 29 has a fourth mounting through hole into which a first circuit fixing bracket 32 ​​is fitted. The external thread at the top of the first circuit fixing bracket 32 ​​is screwed into the internal thread in the circuit board mounting hole 6, so that the signal processing element 29 is mounted on the mounting platform 3. The pins of the speed sensor 27 and the temperature sensor 28 are directly soldered to the signal processing element 29. There are three fourth mounting through holes, and the first circuit fixing brackets 32 are fitted into each of the three fourth mounting through holes, and the three first circuit fixing brackets 32 are fitted into the three circuit board mounting holes 6, respectively.

[0040] The fifth mounting through hole on the flow calculation element 30 is fitted with a second circuit fixing bracket 33. The external thread at the top of the second circuit fixing bracket 33 is screwed into the threaded hole on the bottom surface of the first circuit fixing bracket 32, so that the flow calculation element 30 is mounted on the signal processing element 29 in a suspended manner (the three second circuit fixing brackets 33 and the three first circuit fixing brackets 32 are connected one by one).

[0041] A circuit fixing bolt 34 is embedded in the sixth mounting through hole on the storage element 31. The external thread at the top of the circuit fixing bolt 34 is screwed into the threaded hole on the bottom surface of the second circuit fixing support 33, so that the storage element 31 is mounted on the flow calculation element 30 in a suspended manner (the three circuit fixing bolts 34 and the three second circuit fixing supports 33 are connected one by one). The signal processing element 29, the flow calculation element 30 and the storage element 31 are connected by a flexible circuit board 35.

[0042] The bottom end of the electrical connector 26 is inserted into the third mounting through hole 13, and the top end of the fixing bolt 36 of the electrical connector 26 is screwed into the internal thread of the second mounting through hole 12. An insulating gasket 39 is provided between the electrical connector 26 and the bottom surface of the outer casing 1. The four fixing bolts 36 correspond one-to-one with the four second mounting through holes 12.

[0043] The flow transmitter incorporates a real-time self-diagnostic algorithm based on the correlation between the speeds of the two turbines. Under normal operating conditions, the speed ratio or phase difference between the upstream and downstream turbines remains within a defined empirical / theoretical range. If a single turbine blade is damaged, a bearing becomes abnormally stuck, a sensor fails partially, or large particles become entangled in the fluid, the correlated signal between the two turbines will exhibit a characteristic deviation. The system can immediately trigger alarms (such as "signal synchronization failure" or "turbine malfunction") and can switch to a "limp-home" mode supported by a healthy turbine according to a preset strategy, providing degraded but still reliable flow data. This avoids the risk of "total shutdown" associated with traditional single-sensor flow meters, significantly improving the reliability and maintainability of the measurement system.

[0044] The triggering conditions are as follows: the self-diagnostic system detects an abnormal correlation between the upstream and downstream turbine speed signals (e.g., abnormal speed ratio or significant deviation from the normal range). It determines that the problem may be a single fault, such as one turbine blade being stuck by a foreign object, or a bearing malfunction. However, the system can still receive the valid speed signal from the other turbine.

[0045] Its operating logic is as follows: The signal processing unit analyzes abnormal patterns to determine which turbine or sensor channel is more likely to have a problem. The system automatically switches from "high-precision dual-turbine correlation measurement mode" to "single-turbine degraded measurement mode." In this mode, the system will only rely on the signal from the turbine determined to be "healthy" to calculate the flow rate. Simultaneously, a fault alarm will be explicitly output (e.g., illuminating a specific warning light or outputting a specific status code).

[0046] Because the ability to perform dual-turbine correlation compensation (such as viscosity compensation and velocity distribution compensation) is lost, the measurement accuracy will be lower than in normal conditions, and the measurement range may also be narrower. However, the system can still provide a continuous and trend-correct flow reading within an acceptable error range based on the calibration curve of a healthy turbine. This avoids production interruptions, improves system reliability, and ensures basic operational safety.

[0047] After installing the sensor and flow transmitter, the designed potting fixture 37 should be used to pot the indicated area 38 with adhesive to insulate it and secure the circuit components to prevent loosening, thus improving the flow meter's applicability under complex and harsh conditions such as strong vibration, variable temperature, and variable attitude in aerospace applications. Finally, install the electrical connector 26 as follows... Figure 13 As shown, the flow meter installation process is now complete.

[0048] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An integrated counter-rotating turbine flow sensor, characterized in that, include: Housing components provide airflow guidance and support; A shaft system is disposed within the housing component. The shaft system includes an upstream guide plate, a drive shaft, a tapered guide plate, an upstream turbine, an intermediate transition guide plate, a downstream turbine, a downstream transition guide plate, a downstream guide plate, and a locking nut. One end of the drive shaft is connected to the upstream guide plate. The tapered guide plate, the upstream turbine, the intermediate transition guide plate, the downstream turbine, the downstream transition guide plate, the downstream guide plate, and the locking nut are sequentially mounted on the drive shaft. The shaft system is axially locked and embedded within the housing component by tightening the locking nut. An electrical component, disposed on the housing, is used to monitor the rotational speed of the shaft component propelled by fluid within the housing to determine the flow rate through the counter-rotating turbine flow sensor.

2. The integrated counter-rotating turbine flow sensor according to claim 1, characterized in that, The housing component includes a housing base and a housing cover. The housing base is used to mount the shaft system and the electrical components, and the housing cover provides protection for the electrical components on the housing base.

3. The integrated counter-rotating turbine flow sensor according to claim 2, characterized in that, The housing base includes a flow channel and a mounting platform. The flow channel is used to mount the shaft component, allowing liquid to flow through and drive the shaft component to rotate. The mounting platform is used to mount the electrical components on the flow channel, and is used to detect the rotational speed of the shaft component and analyze the liquid flow rate.

4. The integrated counter-rotating turbine flow sensor according to claim 3, characterized in that, Both ends of the inner wall of the flow channel are machined with bosses for mounting the shaft components; the mounting platform is provided with mounting holes for speed sensors, temperature sensors, circuit boards, and housing covers for mounting the electrical components.

5. The integrated counter-rotating turbine flow sensor according to claim 3 or 4, characterized in that, A square platform is provided on the outer casing, and the outer casing is sealed and installed on the mounting platform by screws passing through the square platform.

6. The integrated counter-rotating turbine flow sensor according to any one of claims 1-4, characterized in that, The drive shaft is screwed into the threaded hole at one end of the upstream guide plate via an external thread at one end; the upstream turbine is rotatably mounted on the drive shaft via an embedded bearing; the downstream turbine has the same structure as the upstream turbine, and the downstream turbine is rotatably mounted on the drive shaft via an embedded bearing.

7. The integrated counter-rotating turbine flow sensor according to claim 3 or 4, characterized in that, The electrical components include a sensor, a flow transmitter, and an electrical connector. The sensor is mounted on the mounting platform to monitor the rotational speed of the shaft components and the liquid temperature in the flow channel. The flow transmitter is mounted on the mounting platform and electrically connected to the sensor to receive and process the sensor signals, and then transmits the data externally through the electrical connector mounted on the housing cover.

8. The integrated counter-rotating turbine flow sensor according to claim 4, characterized in that, The sensor includes a speed sensor and a temperature sensor. The speed sensor is installed in the speed sensor mounting hole, and the temperature sensor is installed in the temperature sensor mounting hole. Both the speed sensor and the temperature sensor are electrically connected to the flow transmitter.

9. The integrated counter-rotating turbine flow sensor according to claim 8, characterized in that, The flow transmitter includes a signal processing element, a flow calculation element, and a storage element. The signal processing element is mounted on the mounting platform, the flow calculation element is mounted on the signal processing element, and the storage element is mounted on the flow calculation element. These elements are used to receive and process the rotation speed signal and temperature signal transmitted by the sensor, and to perform flow calculation using the rotation speed signal and temperature signal based on the built-in flow calculation algorithm. The system stores the physical property database, algorithm formula parameters, and calculated flow data required in the flow calculation algorithm, and finally sends out the flow signal through the connected electrical connector. The flow transmitter has a real-time self-diagnostic algorithm based on the correlation between the speeds of the two turbines.

10. The integrated counter-rotating turbine flow sensor according to claim 9, characterized in that, The signal processing element is mounted on the mounting platform via a first circuit fixing bracket embedded thereon, the flow calculation element is mounted on the signal processing element via a second circuit fixing bracket embedded thereon, and the storage element is mounted on the flow calculation element via a circuit fixing bolt embedded thereon; the signal processing element, the flow calculation element, and the storage element are electrically connected via a flexible circuit board.

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