Additive Flow Sensor with Integral Passageway
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Solution Overview
Problem
Conventional boost venturi sensors for aircraft environmental control systems face accuracy issues due to multiple braze joints and limited cross-section designs, which hinder precise fluid flow measurement.
Innovation Solution
An additively manufactured flow measurement sensing device with a first and second venturi, featuring a first integral passageway with a tapered segment and multiple air inlets, optimized for airflow sampling, eliminating the need for cross-drilling and allowing customizable cross-sections for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cast, forged, and machined components with dip brazing or welding are used to join multiple components, then the sensor can be manufactured using traditional methods, but the accuracy is negatively impacted by multiple braze joints and plugged cross-drill points
Solution Approach 1:
The patent merges multiple separate components (venturi body, passageways, shielding structures) into a single additively manufactured component. This eliminates the need for dip brazing or welding joints between components, removing a major source of measurement error while maintaining structural integrity through the additive manufacturing process itself.
Solution Approach 2:
The patent segments the manufacturing process into additive manufacturing layers, allowing complex internal passageways and external shielding structures to be built integrally without traditional joining methods. The additive process creates internal cross-sections that would be impossible with conventional machining, eliminating the need for cross-drilling and plugging operations.
2Adaptability or versatility
If conventional tooling methods and cross-drilling are used, then traditional manufacturing processes can be employed, but the cross-section is limited to what can be achieved by current tooling methods
Solution Approach 1:
The patent transitions from two-dimensional cross-sectional limitations of conventional machining to three-dimensional freedom of additive manufacturing. Complex internal passageways with varying cross-sections (rectangular, triangular, circular) can be created along the length of the component without requiring multiple tooling setups or cross-drilling operations, enabling optimized airflow sampling geometry.
Solution Approach 2:
The patent changes the manufacturing parameters from subtractive machining constraints to additive manufacturing capabilities. This allows cross-sections to be defined by digital models rather than tooling geometry, enabling arbitrary shapes and internal features to be manufactured directly without tool access limitations or cross-drilling requirements.
3Reliability
If multiple components are joined through dip brazing or welding, then traditional assembly methods can be used, but the seamless design is compromised
Solution Approach 1:
The patent combines multiple functional elements (venturi body, internal passageways, external shielding) into a single monolithic component manufactured through additive processes. This eliminates all braze joints and welding connections, creating a seamless design that prevents leakage and measurement errors at joints while maintaining manufacturability through layer-by-layer construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances measurement accuracy by providing a seamless design with customizable cross-sections and eliminates the need for cross-drilling, enabling precise fluid flow measurement in various applications.
Implementation Method 1
a first venturi having a first shield portion, an elongated portion connected to an outer surface of the first venturi, and a second venturi housed within the first venturi. The first venturi and the second venturi are configured to sample portions of an airflow
Data Source
Figure 1
Figure 2~3B
Figure 4~5A
AI summary
A flow measurement sensing device (10) includes a first venturi (22; 122; 222) having a first shield portion (38; 138), an elongated portion (14) connected to an outer surface of the first venturi (22; 122; 222), and a second venturi (24; 124; 224) housed within the first venture (22; 122; 222). The second venturi (24; 124; 224) has a second shield portion (40; 140) and at least one air inlet (32; 232). The flow measurement sensing device (10) further includes a first integral passageway (30) extending from the air inlet (32; 232) through the elongated portion (14). The first integral passageway (30) has a first segment with a first cross-sectional shape and a segment with a second cross-sectional shape.