Flow Rate Sensor With Magnetic Force Transmission
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Solution Overview
Problem
Existing flowrate sensors for fluid networks, such as aqueducts, face challenges including high energy consumption, accuracy issues, complex installation requirements, and susceptibility to corrosion and damage due to fluid exposure, especially in remote or high-temperature environments with suspended solids.
Innovation Solution
A flowrate sensor design featuring a probe within the duct and a load cell outside, separated by a fluid-tight wall, using magnetic interaction for contactless force transmission, eliminating the need for protective coatings and allowing for accurate, low-consumption measurements without affecting the load cell, which is independent of fluid distribution and speed profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a probe with electrical components is dipped into the fluid for measurement, then flowrate measurement is enabled, but the electrical components are exposed to corrosion and fluid damage
Solution Approach 1:
The device is divided into two separate sections: a fluid-exposed section containing the probe and a protected section containing the electrical components. This segmentation allows the probe to interact with the fluid while keeping sensitive electronics isolated from corrosive environments.
Solution Approach 2:
A non-conductive, electrically inert resin or ceramic sheath acts as an intermediary protective layer between the electrical components and the fluid. This coating transfers the fluid dynamic thrust to the probe while protecting the electrical components from direct fluid contact and corrosion.
2Object-affected harmful factors
If protective coatings are applied to protect electrical components, then corrosion resistance is improved, but the elastic compliance of the probe is reduced
Solution Approach 1:
The protective coating is applied selectively only to the portions of the probe that require protection from fluid contact, rather than coating the entire probe. This localized approach maintains the elastic compliance of the probe structure while providing necessary corrosion protection.
Solution Approach 2:
The coating material is selected with specific properties (non-conductive, electrically inert, flexible) that allow it to protect against corrosion while maintaining the probe's elastic characteristics. The coating thickness and material composition are optimized to balance protection with mechanical performance.
3Reliability
If high-accuracy sensors are used, then measurement reliability is improved, but energy consumption increases
Solution Approach 1:
The device replaces complex electronic sensing systems with a simpler mechanical measurement approach. The probe's elastic deformation under fluid dynamic thrust is directly measured, converting a complex electrical measurement problem into a straightforward mechanical displacement or strain measurement that requires minimal energy.
Solution Approach 2:
The probe structure itself serves as both the sensing element and the measurement mechanism. The elastic deformation of the probe under fluid flow directly provides the measurement signal, eliminating the need for additional active sensing components that would consume energy.
4Measurement precision
If the load cell is placed inside the duct for direct measurement, then measurement accuracy is improved, but the load cell becomes susceptible to corrosion and fluid damage
Solution Approach 1:
The measurement system is segmented into a fluid-exposed probe portion and a protected load cell portion. The probe captures the fluid dynamic thrust while the load cell, positioned outside the fluid environment, measures the force without direct exposure to corrosive conditions.
Solution Approach 2:
A protective barrier or coating acts as an intermediary between the load cell and the fluid environment, allowing force transmission while preventing direct fluid contact with the load cell, thereby maintaining both measurement accuracy and durability.
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
The solution provides a cost-effective, accurate, and reliable flowrate measurement system that can operate for extended periods without frequent maintenance, suitable for extended networks, with reduced energy consumption and enhanced durability against corrosion and mechanical stress.
Implementation Method 1
the probe and the load cell comprise a contactless force transmitting means for transferring the force through the wall, said force responsive to the measuring position, between the probe and the load cell when the probe performs the movement and until the measuring position is maintained, wherein the magnetic interaction means comprises respective magnetic elements that are associated with the probe and/or with the load cell
Data Source
Figure 1~3
Figure 4~9
Figure 10~13
AI summary
A flow rate sensor (10) for a duct (1 ), the sensor comprising a first and a second portion (23,24) that can be mounted to the duct so that such portions respectively protrude inside and outside the duct, wherein a sensors means is provided comprising a probe (40) that is constrained to the first portion (23) and has an engagement member (54) for receiving a fluid dynamic thrust (P) from the fluid, responsive to the flow rate, and is arranged to perform a corresponding measurable displacement (18) from a rest position to a corresponding measuring position, and the sensor also comprising a load cell (30) constrained to the second portion, the load cell that is arranged to receive a force (F) from the probe (40) responsive to the measuring position and configured to maintain a corresponding electric measurement signal, as well as data output means for exporting flow rate data obtained from the signal, where the first and the second portion are fluid-tightly separated by a wall (21), and the probe (40) and the load cell (30) comprises a contactless force transmitting means (47,37), in particular a magnetic force transmitting means, for transferring the force (F) through the wall (21) between the probe (40) and the cell (30). In an exemplary embodiment, the first and the second portions (23,24) are housed within one tubular container body (20) whose first and second parts (20', 20") are respectively housed in the first and in the second portions and respectively protrude inside and outside of the duct (1). In an exemplary embodiment, the load cell is a linear axis load cell, in particular a bending beam or parallel beam type load cell.