Flow Sensor with Static and Stagnation Pressure Ports
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Solution Overview
Problem
Industrial compressed air systems face inefficiencies due to inadequate monitoring, leading to increased costs and downtime, as traditional audits are expensive, infrequent, and impractical for continuous monitoring, necessitating a more proactive and cost-effective solution for real-time fluid flow measurement.
Innovation Solution
A flow sensor with a housing and tube configuration, including static and stagnation pressure ports, coupled with pressure sensors and a wireless communication system, allows for continuous monitoring of fluid flow rate by measuring static and dynamic pressures, temperature, and pipe diameter, enabling real-time data transmission and proactive issue detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional compressed air audits are performed, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple sensing functions (static pressure, stagnation pressure, temperature) into a single integrated flow sensor unit. The sensor assembly merges the tube structure with pressure ports and electronic components, eliminating the need for separate wired sensors and receiver/analyzer equipment used in traditional audits.
Solution Approach 2:
The patent extracts the sensing functions from complex external measurement equipment and integrates them directly into a compact, self-contained sensor unit that can be installed on existing pipes. This extraction simplifies the overall system by removing unnecessary external equipment while maintaining measurement capabilities.
2Measurement precision
If wired sensors are used for compressed air monitoring, then measurement precision is improved, but ease of operation deteriorates due to installation complexity
Solution Approach 1:
The patent removes the complex wired connection system from traditional sensors and replaces it with a wireless communication system. The sensor unit includes an integrated wireless transmitter that eliminates the need for physical wiring to receiver/analyzer equipment, significantly simplifying installation and operation while maintaining precise measurement capabilities.
3Device complexity
If infrequent audits are conducted, then device complexity is reduced, but loss of time increases due to delayed problem detection
Solution Approach 1:
The patent enables continuous monitoring by integrating the sensor directly into the compressed air line with wireless communication capabilities. This allows real-time data transmission without requiring physical access to the sensor, eliminating the need for periodic manual audits and enabling immediate detection of issues such as leaks or flow problems.
Solution Approach 2:
The wireless sensor system provides continuous feedback about compressed air flow and pressure conditions to remote monitoring locations. This real-time feedback mechanism allows operators to detect and respond to issues immediately, transforming the periodic audit model into a continuous monitoring approach that reduces problem detection time.
4Productivity
If multiple sensors are distributed throughout the compressed air network, then productivity is improved through continuous monitoring, but device complexity and cost increase
Solution Approach 1:
The patent designs a universal sensor unit that can be installed at multiple locations throughout the compressed air network using the same basic design. The sensor performs multiple functions (measuring static pressure, stagnation pressure, and temperature) within a single unit, reducing the total number of components needed compared to traditional multi-point monitoring systems.
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 continuous, cost-effective monitoring of compressed air systems, allowing for immediate detection and rectification of issues, reducing downtime and energy consumption, and can be adapted for measuring other fluids or gases.
Implementation Method 1
the moving fluid is brought to rest in the second conduit, relative to the first port, which is not directly exposed to the flow and therefore experiences only the static ambient pressure in the pipe. Because the fluid is brought to rest in the second port and conduit, it has an elevated pressure known as the 'stagnation pressure' or 'total pressure,' as opposed to the lower 'static pressure' at the first port and conduit.
Implementation Method 2
The second, differential pressure sensor measures the difference between the stagnation pressure and the static pressure, also known as the 'dynamic pressure.'
Data Source
AI summary
Flow sensor includes a housing having a chamber and a tube extending therefrom. Static and stagnation pressure ports are located along the tube and open in different directions about a periphery. A first conduit fluidly couples the static pressure port to the chamber, and a first pressure sensor senses the fluid pressure in the chamber. A differential pressure sensor has a first port and a second port in the chamber. The first port senses the fluid pressure in the chamber, and a second conduit fluidly couples the stagnation pressure port with the second port. The second port is more exposed to fluid flow through the pipe relative to the first port. Fluid flow rate through the pipe is determinable based on static fluid pressure sensed by the first pressure sensor, differential pressure measured by the differential pressure sensor, density of fluid in the pipe, and diameter of the pipe.