Flow Measurement Using Multi-Point Deflection Sensing
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Solution Overview
Problem
Existing flowmeters face limitations such as sensitivity to flow profile, temperature, density, and conductivity, inability to handle highly conductive slurries or gases, and pressure drop issues, which restrict their application in various industrial settings.
Innovation Solution
A system comprising a cartridge connected serially to media pipes with displacement sensing devices and a processor, equipped with additional sensors for measuring wear, temperature, vibration, and chemical properties, generating a unique Process Signature to accurately measure flow rates and mass flow without interfering with the pipeline integrity, and accommodating different materials and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electromagnetic flowmeters are used to measure flow, then no moving parts and unobstructed flow are achieved, but the method only works for low conductive liquids and cannot handle highly conductive slurries or gases
Solution Approach 1:
The patent replaces electromagnetic measurement with a mechanical deflection-based measurement system. A flexible diaphragm or membrane deflects in response to flow-induced pressure changes, and this mechanical deflection is converted to an electrical signal by a capacitive or piezoelectric sensor, enabling measurement of non-conductive fluids like gases and slurries
Solution Approach 2:
The patent changes the measurement parameter from electrical conductivity (electromagnetic) to mechanical deflection (pressure-based). By measuring the deflection of a flexible element rather than relying on fluid conductivity, the system can handle gases, highly conductive slurries, and other fluids that are incompatible with electromagnetic flowmeters
2Adaptability or versatility
If differential pressure flow meters are used to measure flow, then universal use for liquids, gases and steams is achieved, but the pressure drop caused may be inhibitive for some applications
Solution Approach 1:
The patent uses a flexible diaphragm or membrane as the sensing element. This thin flexible film deflects in response to flow-induced pressure changes, providing a low-resistance path for fluid flow while still enabling accurate measurement, thus minimizing pressure drop compared to traditional differential pressure meters with restrictive orifices
Solution Approach 2:
The patent employs vibratory elements such as a vibrating diaphragm or membrane whose vibration characteristics change with flow-induced pressure. This allows flow measurement through dynamic vibration analysis rather than static pressure differential, reducing energy loss while maintaining versatility across different fluid types
3Measurement precision
If Coriolis mass flowmeters are used to measure mass flow, then highly accurate measurements are achieved, but the diameter cannot exceed approximately 6" and materials in the design are highly limited
Solution Approach 1:
The patent segments the measurement system into a flexible sensing diaphragm and a separate rigid housing structure. This allows the sensing element to be small and flexible for accurate measurement while the housing can accommodate large pipe diameters and various materials, overcoming the size and material constraints of Coriolis meters
Solution Approach 2:
The patent uses a flexible diaphragm or membrane as the core sensing element, which can be manufactured in various sizes and materials to match different pipe configurations. This flexible film approach eliminates the rigid tube constraints of Coriolis meters, allowing adaptation to large diameters and chemically aggressive environments through material selection
4Temperature
If turbine flowmeters are used to measure flow, then viability at extreme temperatures and pressures is achieved, but they cannot be used in high viscosities and are extremely sensitive to contamination
Solution Approach 1:
The patent uses a flexible diaphragm with no internal moving parts that could be affected by viscosity or contamination. The diaphragm simply deflects in response to pressure changes, making the measurement insensitive to fluid viscosity and contamination, while the housing can be designed to withstand extreme temperatures and pressures
Solution Approach 2:
The patent extracts the turbine rotor and blades from the measurement system, replacing them with a flexible diaphragm sensing element. This removal of sensitive moving parts eliminates the problems of viscosity sensitivity and contamination while maintaining the ability to operate in extreme conditions through robust housing design
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 reliable, consistent, and repeatable measurement of flow rates and mass flow, insensitive to conductivity and temperature changes, with no pressure drop, and capable of handling chemically and physically aggressive media, providing critical data for process analysis and control.
Implementation Method 1
a flow inducing a differential pressure across an aperture in the pipe
Implementation Method 2
a displacement sensing device to detect displacement changes of the cartridge
Implementation Method 3
Differential pressure flow meters use Bernoulli's equation to measure the flow across an aperture in a pipe. The small aperture causes a pressure drop that is measured by two pressure gauges. When the flow increases, a greater pressure drop is created. Bernoulli's equation states that the pressure drop is proportional to the square of the flow rate.
Data Source
Figure 1~2
Figure 3~4A
Figure 4B~4C
AI summary
Apparatus and methods for designing a system that measures deflection at multiple points and in various axes and how it relates to flow measurement are described. A system for continuously measuring the mass flow of a media includes one or more cartridges, one or more displacement sensing devices, and a processor. The one or more cartridges are connected serially between an inflow and outflow media pipe. The one or more displacement-sensing devices is configured to detect displacement changes of the one or more cartridges at two or more separate points on the cartridge(s) when the media flows through the cartridge(s). The processor is configured to calculate the flow of the media based on the detected displacement changes of the one or more cartridges at the one or more separate points.