Fluid flow device with discrete point calibration flow rate-based remote calibration system and method
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Solution Overview
Problem
Current fluid flow measurement devices are expensive and have limited turndown ratios, making them ineffective for accurately measuring low fluid flows, particularly in HVAC systems, leading to energy inefficiency and discomfort due to the inability to regulate air flow accurately.
Innovation Solution
A fluid flow measurement and control system utilizing a multi-stage damper with a variable opening mechanism, coupled with a controller that adjusts the opening area based on pressure differentials and flow coefficients, enabling precise measurement and control of fluid flow across a wide range, and incorporating advanced sensors and actuators for enhanced accuracy and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional fluid flow measurement devices are used, then measurement capability is provided, but cost is high and turndown ratio is limited
Solution Approach 1:
The patent replaces conventional mechanical flow measurement devices with a system that uses pressure differential sensors and electronic computation. Instead of using complex mechanical flow meters, the invention uses simple pressure sensors combined with a controller that calculates flow rate based on pressure differentials and damper position, thereby reducing device cost while maintaining measurement accuracy
Solution Approach 2:
The flow measurement system is integrated into the existing damper assembly, allowing the damper to serve dual functions: flow control and flow measurement. The same pressure sensors and controller used for damper operation are utilized to measure flow rates, eliminating the need for separate measurement devices and reducing overall system cost
2Measurement precision
If conventional fluid flow measurement devices are used, then measurement capability is provided, but turndown ratio is limited
Solution Approach 1:
The system dynamically adjusts the damper opening based on computed flow rates and operational requirements. The electronic controller continuously monitors pressure differentials and calculates optimal damper positions, enabling the system to adapt to a wide range of flow conditions including very low flows, thereby achieving a high turndown ratio
Solution Approach 2:
The system implements closed-loop feedback control where pressure sensors continuously monitor flow conditions, the controller computes the actual flow rate, and the damper position is adjusted accordingly. This feedback mechanism enables accurate measurement and control across a wide turndown ratio by constantly optimizing the measurement and control parameters
3Measurement precision
If HVAC systems run at higher flows to maintain accuracy, then measurement accuracy is preserved, but energy consumption increases
Solution Approach 1:
The electronic feedback control system continuously monitors actual flow rates and adjusts damper positions to maintain desired flow levels. This enables the HVAC system to operate at lower, more energy-efficient flows while maintaining measurement and control accuracy through real-time adjustments based on computed flow data
Solution Approach 2:
By replacing mechanical flow control mechanisms with electronic computation and control, the system can precisely regulate flow at lower levels without the energy penalties associated with mechanical systems. The electronic controller optimizes damper positions to minimize energy consumption while maintaining required flow accuracy
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 system provides a high turndown ratio, enabling precise measurement and control of fluid flows, reducing energy consumption, and improving comfort by allowing for accurate regulation of air flow, while also simplifying HVAC system designs and reducing manufacturing costs.
Implementation Method 1
determine a pressure differential based on a first pressure obtained between the first and second sensors
Data Source
AI summary
A method/structure for calibrating a product fluid flow device having one or more apertures with aggregate area Ao, where fluid flows along a fluid flow path therethrough in response to pressure differentials ΔP across the apertures. Calibration is effected relative to a calibration fluid flow device having a geometry and operational parameters corresponding to those of the product fluid flow device. A piecewise curved calibration controller establishes calibration conditions and generates a discrete point calibration flow rate (dpCFR) Function by measuring at a sparse set of points in a range of interest and determining a piecewise curved mathematical representation of fluid flow through the calibration fluid flow device. Data representative of the CFR function is transferred to a product blade controller, which processes the mathematical representation, and controls fluid flow through product fluid flow device based on values extracted from the received dpCFR Function.