Flap-Blade Flow Regulator With Force Sensing for Low-Flow Accuracy
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Solution Overview
Problem
Conventional electronic volume flow controllers face limitations in measurement and control accuracy, especially for small volume flows, due to large variations in measurement signals and hysteresis issues, which result in significant inaccuracy and inefficiency.
Innovation Solution
The implementation of a force sensor that extends over the flap leaf, providing continuous characteristic curves with reduced spread between maximum and minimum values, and a flow sensor that averages force over a larger area, making measurements less sensitive to local disturbances and fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure difference measurement elements are arranged at a distance upstream and downstream of the damper blade, then measurement is not falsified by disturbances in air flow, but measurement and control accuracy for small volume flows remains limited with large spread between maximum and minimum measurement values
Solution Approach 1:
The patent extracts the measurement function from the traditional pressure difference measurement across the damper blade and relocates it to the damper blade surface itself. By placing measurement openings directly on the blade, the system captures local flow characteristics that are more stable and less susceptible to disturbances, thereby improving measurement reliability while maintaining accuracy.
Solution Approach 2:
The patent transitions from one-dimensional pressure difference measurement (upstream-downstream) to two-dimensional surface measurement on the damper blade. By distributing measurement openings across the blade surface and measuring local pressures at multiple points, the system captures flow characteristics in a new spatial dimension, reducing signal spread and improving measurement stability.
2Measurement precision
If measuring elements are arranged directly on the flap leaf, then continuous characteristic curves with reduced spread are achieved, but sensor lines must be flexible and exposed to changing bending stresses
Solution Approach 1:
The patent merges the measurement openings with the damper blade structure itself. The openings are integrated into the blade surface, and the pressure measurement points are combined with the blade's structural elements. This integration eliminates the need for separate sensor lines and flexible connections, reducing device complexity while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces a rigid plate as an intermediary structure that carries the measurement openings and connects to the pressure measurement system. This rigid plate serves as a stable platform for measurements and eliminates the need for flexible sensor lines, as the rigid structure can be directly connected to stationary pressure sensors through fixed openings in the damper blade.
3Ease of manufacture
If point-by-point pressure measurements are used, then measurement setup is simplified, but disturbances in flow pattern easily lead to inaccuracies in volume flow measurement
Solution Approach 1:
The patent segments the measurement process by distributing multiple measurement openings across different locations on the damper blade surface. Instead of relying on a single point measurement, the system uses multiple segmented measurement points that collectively capture the overall flow pattern, reducing the impact of local disturbances and improving measurement accuracy.
Solution Approach 2:
The patent applies local quality by positioning measurement openings at specific locations on the damper blade where flow characteristics are most representative and stable. Each measurement point is strategically placed to capture local flow conditions that reflect the overall volume flow, maintaining measurement simplicity while improving accuracy through optimized local measurement locations.
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
This configuration achieves high measurement accuracy across the entire volume flow range, with reduced inaccuracy even at small volume flows, and enhances the controller's ability to maintain precise control and tight shut-off positions.
Implementation Method 1
When the air flows around the flap leaf, which is positioned at an angle in the flow line, a closing moment occurs due to aerodynamic effects
Implementation Method 2
a flow sensor which extends over at least part of the flap leaf... the force generated by the flow is averaged over a relatively large flow cross-section
Data Source
Figure 1~2
Figure 3~4
Figure 5~8
AI summary
Volume flow controller with a flap blade (14) pivotably arranged in a flow line (10), a sensor arranged on the flap blade for determining the volume flow through the flow line, a motor drive (26) for pivoting the flap blade (14), and an electronic control unit (30) for controlling the drive (26) depending on a signal from the sensor, characterized in that the sensor is a force sensor (20) which is actuated by a flow sensor (24) extending over at least a part of the flap blade (14).