Bending Beam Flow Sensor for Granular Media
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Solution Overview
Problem
Existing flow sensors for granular media in abrasive applications wear quickly due to contamination and require complex maintenance, leading to accuracy and performance issues, especially with hinges, bearings, and delicate wiring.
Innovation Solution
A simple bending beam flow sensor that deflects in response to media flow, eliminating the need for hinges, strain gauges, and bearings, with a proximity sensor measuring deflection to generate an electrical signal, allowing for easy replacement and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow sensors with hinges, bearings, or strain gauges are used to measure granular media flow rate, then measurement capability is provided, but the device wears quickly and requires complex maintenance
Solution Approach 1:
The invention extracts the measurement function from complex mechanical components (hinges, bearings, strain gauges) and implements it through a simple deflectable member that responds to media flow. The proximity sensor only measures the deflection position without physical contact with the media, separating the measurement function from the wear-prone components.
Solution Approach 2:
The invention replaces complex mechanical measurement systems with a combination of a simple deflectable member and a proximity sensor. The proximity sensor uses electromagnetic or optical fields to measure deflection without mechanical contact, eliminating wear from mechanical components while maintaining measurement capability.
2Measurement precision
If traditional flow sensors with delicate wiring and bearings are used, then flow measurement is achieved, but maintenance becomes difficult and time-consuming
Solution Approach 1:
The invention segments the flow sensor into modular components: a deflectable member mounted in a branch of the flow path and a proximity sensor mounted on the housing. This segmentation allows individual components to be easily replaced without affecting the entire sensor assembly, simplifying maintenance procedures.
Solution Approach 2:
The deflectable member is designed as a simple, inexpensive component that can be easily replaced when worn. Its simplicity allows for quick replacement without requiring specialized tools or procedures, making it effectively a disposable component that maintains low maintenance costs.
3Ease of repair
If a simple deflectable member is used instead of complex sensors, then maintenance becomes easier, but measurement accuracy may be compromised
Solution Approach 1:
The deflectable member serves as an intermediary that translates media flow into positional displacement. The proximity sensor then accurately measures this displacement without direct contact with the media. This intermediary approach allows the simple deflectable member to maintain measurement accuracy while being easy to replace.
Solution Approach 2:
The proximity sensor uses non-contact electromagnetic or optical fields to measure the position of the deflectable member, replacing mechanical measurement systems. This substitution maintains high measurement precision while eliminating the need for complex mechanical components that would compromise accuracy.
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 provides accurate and reliable flow rate measurement without wear-related issues, enabling effective process control and easy maintenance by removing and replacing the beam without disrupting operations.
Implementation Method 1
responsive to flow of media in the flow path to increase and decrease deflection of the beam in response to increasing or decreasing flow of media through said flow path
Implementation Method 2
A proximity sensing device measures deflection of the beam and generates an electrical signal which varies in response to deflection of the deflectable member
Data Source
AI summary
An apparatus for treating a workpiece with a granular media includes a hopper for storing media and discharging the media into a flow path. A source of compressed air mixes with the media, which is forced through a nozzle for directing media onto the workpiece. A flow sensor includes a beam extending into the flow path and is responsive to flow of media in the flow path to increase and decrease deflection of the beam in response to increasing or decreasing flow of media through said flow path. A proximity sensing device measures deflection of the beam and generates an electrical signal which varies in response to deflection of the beam. The flow path is defined by a conduit having a branch in which the beam is mounted. One end of the beam is mounted on a base in the branch. The base is mounted on a cap closing an open end of the branch, permitting the beam to be easily removed and changed when necessary.