Flow Control Valve with Float and LVDT Feedback
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Solution Overview
Problem
Existing devices, such as rotameters and turbine meters, are inadequate for accurately measuring fluid flowrates at high pressures and low turn-down ratios, highlighting a need for a reliable solution to control and measure fluid flowrates across a wide range of pressures.
Innovation Solution
A flow control valve assembly with a manifold, float assembly, and LVDT sensor system that measures fluid flow by detecting the displacement of a float within a variable area chamber, using principles of conservation of energy and continuity equations to calculate flowrate, and includes a pressure control circuit to manage inlet flow pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotameter is used to measure fluid flowrate, then the device structure is simple, but it cannot be used at high pressures because it is typically made out of glass
Solution Approach 1:
The invention changes the material parameter from glass to stainless steel, enabling the device to withstand high pressures while maintaining the simple rotameter structure. The stainless steel construction allows the variable area chamber to be pressurized without breaking, thus resolving the contradiction between structural simplicity and high pressure reliability.
2Reliability
If turbine meters or venturi tubes are used to measure flowrate, then the device can handle high pressures, but they do not accurately measure flowrates at the low end (turn-down ratios below 20-to-1)
Solution Approach 1:
The invention incorporates a magnetic float with a magnet that provides feedback on the exact position of the float within the variable area chamber. The measuring device detects the magnetic field position, providing precise measurement signals even at low flowrates. This feedback mechanism enables accurate measurement across the entire flow range, including low end flowrates, while maintaining high pressure capability through the stainless steel construction.
3Measurement precision
If a variable area meter is used to measure flowrate, then the cross-sectional area can vary to provide measurement, but the device cannot accurately measure at low turn-down ratios
Solution Approach 1:
The invention replaces the traditional mechanical reading mechanism with a magnetic field-based measuring device. The magnetic float responds to flowrate changes by moving to different positions, and the measuring device detects these positions through magnetic field interactions without mechanical contact. This substitution enables precise measurement across a wide turn-down ratio range, as the magnetic detection system can accurately sense even small float displacements that occur at low flowrates.
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 accurate measurement and control of fluid flowrates at high pressures and low turn-down ratios, providing precise flowrate calculations and adaptable to various applications through modular design and robust construction.
Implementation Method 1
using principles of conservation of energy and continuity equations to calculate flowrate
Implementation Method 2
using principles of conservation of energy and continuity equations to calculate flowrate
Implementation Method 3
A measuring device is positioned at the bottom of the at least one manifold, and spaced apart from the magnet
Implementation Method 4
a lower end that is connected to a magnet
Data Source
AI summary
A flow control valve assembly has at least one manifold having an inlet flow port, an outlet flow port, and a flow channel provided there between, the flow channel having an inlet chamber, a variable area chamber and an outlet chamber, with fluid flowing from the inlet flow port to the inlet chamber, the variable area chamber and the outlet chamber, in that order, before exiting the outlet flow port. The flow control valve assembly further includes a float assembly having a float extending through the flow channel and which is limited for its movement inside the variable area chamber, a connecting rod extending through the flow channel and which has an upper end that is connected to the float and a lower end that is connected to a magnet. A measuring device is positioned outside the fluid chamber at the bottom of the at least one manifold, and spaced apart from the magnet.