Flexible Cartridge Density Sensor for Abrasive Slurries
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Solution Overview
Problem
Current methods for continuously measuring the density of flowing media, such as nuclear, ultrasound, and auto-sampling techniques, face limitations including real-time measurement inaccuracy, limited application range, safety restrictions, and vulnerability to abrasive or corrosive substances, particularly in industries like mining and dredging.
Innovation Solution
A system comprising a cartridge connected between inflow and outflow pipes with a displacement sensing device, pressure sensor, temperature sensor, and processor to calculate density and specific gravity of liquids, capable of handling abrasive slurries and providing real-time, accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If nuclear density meters are used to measure density of flowing media, then density measurement capability is provided, but safety restrictions and transport limitations occur
Solution Approach 1:
The patent replaces nuclear measurement systems with a mechanical measurement system using a flexible cartridge that deflects under the weight of the fluid. This mechanical approach eliminates safety restrictions and transport limitations associated with nuclear materials while maintaining density measurement capability through force sensing.
Solution Approach 2:
The patent introduces a flexible cartridge as an intermediary element between the fluid and the measurement system. The cartridge deflects in response to fluid weight, converting the measurement problem into a mechanical displacement problem that can be solved with non-nuclear force sensors, thereby eliminating nuclear safety issues.
2Measurement precision
If Coriolis meters are used to measure density of fluid medium, then density measurement is enabled, but abrasive slurries erode the bent pipe quickly
Solution Approach 1:
The patent uses a flexible cartridge made of durable material that can withstand abrasive slurries. The flexible nature of the cartridge allows it to deflect under fluid weight without the erosion problems of rigid bent pipes in Coriolis meters, improving reliability in abrasive environments while maintaining measurement capability.
Solution Approach 2:
The flexible cartridge is designed as a replaceable, cost-effective component that can be easily replaced when worn by abrasive slurries. This approach is more economical than replacing expensive Coriolis meter bent pipes, maintaining measurement capability while reducing long-term costs and downtime.
3Ease of operation
If ultrasound or microwave sensors are used to measure density, then non-contact measurement is achieved, but measurement accuracy deteriorates above 15% solids
Solution Approach 1:
The patent replaces ultrasound and microwave sensing with a mechanical force measurement system. The flexible cartridge directly measures the weight of the fluid through mechanical deflection, which remains accurate regardless of solids concentration. This mechanical approach eliminates the signal irregularity problems that occur with acoustic and electromagnetic methods in high-solids environments.
4Measurement precision
If auto-sampling is used to measure density of continuous flowing media, then laboratory analysis is enabled, but measurement time increases to 24 h or more
Solution Approach 1:
The patent enables the measurement system to perform its own measurement function continuously in-line without requiring sample collection, transport, or laboratory analysis. The flexible cartridge measures density directly in the flowing media in real-time, eliminating the 24-hour or longer wait times associated with auto-sampling and laboratory procedures.
Solution Approach 2:
The patent implements continuous in-line measurement where the flexible cartridge continuously measures fluid density as it flows through the system. This eliminates the intermittent, time-consuming sample collection and analysis process, providing continuous real-time data for process control and decision-making.
Data Source
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AI summary
Apparatus and methods for the continuous measurement of specific gravity or density of solids in a fluid medium are disclosed. A system for continuous measurement of density of a flowing medium comprises a cartridge connected in series to an inflow pipe and an outflow pipe, a displacement sensing device adapted to monitor displacement changes of the cartridge when a medium flows through the cartridge, a base configured to provide a support for the displacement sensing device, a pressure sensor, a temperature sensor, and a processor configured to calculate density of the flowing media based on measured displacement change, temperature and pressure.