Flow Control Assembly with Pressure Sensor for Precise Regulation
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Solution Overview
Problem
Prior flow control devices fail to accurately and precisely measure flow rates in real time due to the presence of variable orifices, which prevents precise regulation and adjustment of fluid flow despite varying fluid pressures.
Innovation Solution
A flow control assembly with a casing, piston, and biasing member, equipped with a pressure sensor that measures fluid pressure both upstream and within the assembly, allowing for accurate calculation of flow rates without interference from variable orifices, using a sensor such as a pressure transducer to provide precise pressure readings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a variable orifice (piston inlet or casing outlet) is used to control flow, then the device can automatically regulate flow under varying pressures, but accurate and precise real-time flow rate measurement becomes impossible
Solution Approach 1:
A second piston with a fixed orifice is introduced as an intermediary measurement element. This fixed orifice provides a reference flow path that maintains a stable pressure differential relationship, enabling accurate flow rate calculation through pressure sensing without being affected by the variable orifice's position changes
Solution Approach 2:
The mechanical flow measurement approach (directly measuring flow through variable orifices) is replaced with a pressure-based measurement system. Pressure sensors measure the pressure differential across the fixed orifice, and flow rate is calculated using the known orifice characteristics and pressure data, eliminating the need for direct mechanical flow measurement
2Measurement precision
If pressure sensors are positioned upstream and downstream of the flow control device, then flow rate can be calculated, but the variable orifice between the pressure readings prevents accurate measurement
Solution Approach 1:
A fixed orifice structure is positioned between the pressure sensing points to serve as an intermediary measurement element. This fixed orifice creates a known flow restriction with stable characteristics, allowing the pressure differential measured across it to accurately represent flow rate regardless of the variable orifice position elsewhere in the device
Solution Approach 2:
The flow control device is segmented into distinct functional zones: a measurement zone with the fixed orifice and pressure sensors for accurate flow measurement, and a control zone with the variable orifice for flow regulation. This segmentation allows independent optimization of measurement accuracy and flow control functionality
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
Enables fine-tuning of flow devices to achieve desired flow rates by accurately measuring and adjusting for minute variations in tolerances and component interactions, ensuring precise flow regulation despite pressure changes.
Implementation Method 1
operate via a pressure differential between the upstream portion of the device and the downstream portion of the device
Implementation Method 2
as the differential pressure increases across the piston and compresses the biasing means causing the casing outlet to be closed off by the edge of piston
Implementation Method 3
a means, such as a spring, for biasing said casing with said piston
Data Source
AI summary
A flow control device for automatically controlling the flow of a fluid at a predetermined rate that is capable of taking measurements of the pressure of the fluid within the device while the device is functioning and that is capable of real-time adjustment of the flow rate is provided. Said device includes a casing having a casing outlet, a piston having a piston inlet and an edge, wherein said piston interfaces with the casing in a manner such that the edge is cooperable with the casing outlet to control the flow of fluid through the device. A biasing member, such as a spring, for biasing the casing with the piston is further included, as is a sensor, such as a pressure transducer, for measuring the pressure within the interior of the casing.