Flow Sensor Partitions for Extended Range
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Solution Overview
Problem
Flow sensors often become saturated when exposed to higher mass volumetric flow rates, limiting their operational range and leading to unstable and unreliable output signals in various applications.
Innovation Solution
The flow sensor assembly includes a housing with partitions that define multiple fluid sub-passages, allowing the sensor to operate at higher mass volumetric flow rates while maintaining a stable and repeatable output signal, achieved by laminarizing the fluid flow and reducing turbulence through the adjustment of sub-passage geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow sensor is exposed to higher mass volumetric flow rates, then the flow rate range is increased, but the sensor becomes saturated and output signal stability deteriorates
Solution Approach 1:
The flow channel is divided into multiple parallel sub-channels using partitions, allowing the total flow to be distributed across multiple pathways. This segmentation prevents any single sensor from becoming saturated while maintaining the ability to measure higher overall flow rates, thus resolving the contradiction between extended flow range and signal stability.
2Productivity
If the flow channel geometry is modified to increase flow capacity, then the flow rate range is enhanced, but turbulence increases and sensor reliability decreases
Solution Approach 1:
By segmenting the flow channel into multiple narrower sub-channels, the Reynolds number in each sub-channel is reduced, promoting laminar flow conditions. This segmentation approach allows the system to handle higher total flow rates while maintaining laminar flow in individual channels, thus preventing turbulence-related measurement errors.
Solution Approach 2:
The partitions create localized flow paths with specific geometric characteristics optimized for laminar flow. Each sub-channel has controlled dimensions and geometry that promote smooth, laminar flow conditions locally, even when the overall system handles high flow rates, thereby eliminating turbulence as a harmful factor.
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
This configuration enables the flow sensor to handle increased flow rates without saturation, providing a consistent, reliable, and stable output signal by promoting laminar flow and reducing noise, thus enhancing the sensor's range and sensitivity.
Implementation Method 1
A transducer or an electronic sensor is located within the flow passage, which measures mass flow rate
Implementation Method 2
measures the flow rate of a fluid equally in either flow direction
Data Source
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AI summary
Flow sensor assemblies (38) having increased flow range capabilities are disclosed. In one illustrative embodiment, a flow sensor assembly (38) includes a housing (82) with an inlet flow port, an outlet flow port, and a fluid channel (12) extending between the inlet flow port and the outlet flow port. One or more partitions (48, 50) are provided in the fluid channel (12) of the housing (82) to define two or more fluid sub-passages (52). A flow sensor (10), for sensing a measure related to a flow rate of a fluid flowing through the fluid channel (12), is positioned in one of the two or more fluid sub-passages (52, 54, 56). In some cases, the cross-sectional area of each of the two or more fluid sub-passages (52, 54, 56) may be substantially the same, but this is not required. The housing (82) may be formed from a single molded part defining the inlet and outlet flow ports, at least a portion of the fluid channel (12), and one or more of the partitions (48, 50). In this case, a top cover (60) may be provided and mounted to the housing (82) to define the remaining portion of the fluid channel (12), if desired.