Dual-Sensor Flow Meter with Overlapping Calibration Ranges
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Solution Overview
Problem
Mass flow meters struggle with accurate volumetric flow rate measurements due to fluid condition variations such as density and composition changes, while vortex-based flow meters are limited by low flow rate measurement capabilities.
Innovation Solution
A system with two sensors, one sensitive to fluid conditions and the other less sensitive, that automatically generates a calibration relationship for varying conditions by overlapping flow rate ranges, allowing for accurate flow rate determination across a wide dynamic range without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mass flow meters are used for volumetric flow rate measurements, then mass flow rate measurement is provided, but measurement accuracy deteriorates when fluid conditions vary such as density and composition changes
Solution Approach 1:
The flow measurement system is segmented into two distinct measurement modes: mass flow rate measurement for higher flow rates and volumetric flow rate measurement for lower flow rates. This segmentation allows each measurement mode to operate in its optimal range, with the mass flow meter providing accurate measurements at higher flows and the volumetric flow meter taking over at lower flows where vortex formation becomes inadequate.
Solution Approach 2:
The system combines two different flow measurement technologies (mass flow meter and vortex-based volumetric flow meter) into a composite measurement system. Each technology has complementary strengths: the mass flow meter provides accuracy across varying fluid conditions, while the volumetric flow meter provides direct volumetric measurement capability. The system integrates both to achieve superior overall performance.
2Measurement precision
If vortex-based flow meters are used for volumetric flow rate measurements, then direct volumetric measurement is provided with insensitivity to fluid conditions, but measurement capability deteriorates at low flow rates below vortex formation threshold
Solution Approach 1:
The system dynamically switches between two measurement modes based on the current flow rate conditions. When flow rate is above the vortex formation threshold, the system operates in volumetric measurement mode using vortex frequency. When flow rate drops below the threshold, the system automatically transitions to mass flow rate measurement mode, ensuring continuous accurate measurement across the entire flow range.
Solution Approach 2:
The system changes the measurement parameter being used based on flow conditions. At higher flow rates, it measures vortex frequency to determine volumetric flow rate directly. At lower flow rates, it switches to measuring mass flow rate and uses that as the primary measurement parameter. This parameter switching allows the system to maintain measurement accuracy across varying flow conditions.
3Measurement precision
If dual sensor system with overlapping flow rate ranges is implemented, then accurate flow rate determination across wide dynamic range is achieved, but device complexity increases
Solution Approach 1:
The system merges two flow measurement technologies into a single integrated flow meter device. The mass flow meter and vortex-based volumetric flow meter are combined in one housing with overlapping measurement ranges, allowing seamless transition between measurement modes. This merging eliminates the need for separate measurement devices and provides continuous coverage across the entire flow range.
Solution Approach 2:
The flow meter system is designed with multi-functionality to perform both mass flow rate measurement and volumetric flow rate measurement within a single device. The system can automatically select the appropriate measurement mode based on current flow conditions, providing universal measurement capability that adapts to different flow rates and fluid conditions without requiring multiple separate instruments.
Data Source
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AI summary
A system, comprising a first sensor 104 that generates a first output signal representative of a first flow rate measurement in a first flow rate range of a fluid 102, a second sensor 106 that generates a second output signal representative of a second flow rate measurement in a second flow rate range of the fluid that at least partially overlaps the first flow rate range of the fluid to form a partially overlapping region, a data repository 122 storing a first calibration relationship 124 corresponding to a first condition of the fluid and a second calibration relationship 126 corresponding to a second condition of the fluid, wherein the first calibration relationship and the second calibration relationship correspond to the first sensor, and a processing subsystem 120 that automatically generates a third calibration relationship when the second flow rate measurement falls in the partially overlapping region, wherein the third calibration relationship corresponds to a third condition of the fluid based at least on the first calibration relationship, the second calibration relationship, the first output signal and the second output signal.