Bent Flow Path Sensor Module for Accurate Insertion-Type Vortex Flow Measurement
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Solution Overview
Problem
Conventional 'insertion-type' vortex flowmeters face challenges in achieving high measurement accuracy for flow velocities and volume or mass flow rates, especially in pipelines with nominal diameters over 100 mm, due to the compromise between flow conditioner effectiveness and installation dimensions, resulting in measurement errors and reduced accuracy with short flow sections.
Innovation Solution
A sensor module design with a prismatic or cylindrical flow path having a largest inside diameter smaller than the pipeline's smallest diameter, featuring a bluff body for generating Karman vortices, and a converter element that processes sensor signals to achieve accurate flow measurements, while maintaining compact installation dimensions by aligning the intermediate flow path perpendicular to the pipeline axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional insertion-type vortex flowmeters are used in pipelines with large nominal diameter (DN 100 or larger), then the installation dimensions are reduced, but the measurement precision deteriorates due to compromise between flow conditioner effectiveness and installation dimensions
Solution Approach 1:
The flow path is designed with a bent configuration where the intermediate region's central axis is non-parallel (perpendicular) to the inlet and outlet regions. This dimensional change allows the flow path to achieve sufficient length for flow conditioning while maintaining a compact overall sensor module size that can be inserted into large diameter pipelines.
Solution Approach 2:
The sensor module with its bent flow path is nested within the pipeline lumen, allowing the complete flow measurement system including flow conditioner, bluff body, and transducer to be contained within a compact insertion-type structure that fits inside large diameter pipes without requiring external mounting.
2Volume of moving object
If the flow path intermediate region is aligned parallel to the pipeline axis, then the installation dimensions are minimized, but the flow measurement accuracy deteriorates due to insufficient flow conditioning
Solution Approach 1:
The intermediate region of the flow path is oriented perpendicular to the inlet and outlet regions, creating a bent configuration. This dimensional change enables the flow path to achieve sufficient length for proper flow conditioning while keeping the sensor module compact and suitable for insertion into pipelines.
3Device complexity
If short flow sections are used in insertion-type vortex flowmeters, then the installation complexity is reduced, but the measurement precision deteriorates due to inadequate flow profile development
Solution Approach 1:
The bent flow path design dynamically adapts the flow profile through its geometry, using the perpendicular intermediate region to redirect and condition the flow. This dynamic flow conditioning within a compact structure achieves accurate measurements without requiring long straight run sections upstream or downstream.
Solution Approach 2:
By changing the orientation of the intermediate flow path region to be perpendicular rather than parallel to the inlet/outlet, the design achieves sufficient flow conditioning length within a short overall module length, eliminating the need for complex installation requirements.
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 sensor module enables accurate reproduction of flow measurements with a measuring accuracy of more than 99% over the largest possible measuring range and a measurement error of less than 1%, even with short flow sections, by optimizing the flow path geometry and bluff body placement within the pipeline.
Implementation Method 1
to generate vortices arranged in a so-called Karman vortex street within the portion of the fluid flow flowing immediately downstream of the baffle
Data Source
Figure 1
Figure 2
AI summary
The sensor module (S) is used to record at least one parameter, for instance a flow velocity and/or a volume flow rate, of a fluid (FS) flowing in a pipeline and for this purpose comprises a main body (GS), which is placed in a lumen of the pipeline and has a flow path (KS), which extends therein from an inlet opening (ES) to an outlet opening (AS) remote from the latter and therefore communicates with the lumen of the pipeline and is intended to guide a fluid partial volume (FS') branched off from the fluid flowing in the pipeline, as well as a converter element (Ws) which is arranged on the flow path and is intended to generate at least one sensor signal which is influenced by the fluid guided in the flow path. The flow path has an inflow region (EK) which opens into the inlet opening, an outflow region (AK) which opens into the outlet opening, and a straight intermediate region (ZK) which communicates with the inflow region and the outflow region. In the sensor module according to the invention, the flow path is also designed such that an imaginary central axis (LZ) of the intermediate region is not parallel to an imaginary central axis of the inflow region (LE) and/or is not parallel to an imaginary central axis of the outflow region (LA).