Fluid Flow Sensor Array for Detecting Material Deposits

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Solution Overview

Problem

Existing technologies face challenges in accurately detecting material deposits within fluid flow conduits due to geometric constraints, which can lead to fluid flow inhibition and system clogs.

Innovation Solution

A fluid flow sensor assembly featuring an array of pairs of temperature sensors arranged in multiple rows and columns, spaced apart along the primary flow direction, and a mounting device for secure attachment to the conduit, along with optional features like a heater and insulation, to detect material deposits by monitoring thermal responses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Difficulty of detecting and measuring

If scopes or cameras are inserted within the fluid flow conduit to monitor deposits, then deposit detection capability is improved, but the geometry of the conduit and deposits may inhibit accurate detection

Engineering Contradiction:

Improvedeposit detection capabilityVSAvoiddetection accuracy

Core Design Contradiction:

Difficulty of detecting and measuringVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical/optical inspection systems (scopes or cameras) with a thermal sensing system that uses temperature sensors to detect material deposits. The sensor assembly measures temperature differentials caused by deposits on the conduit exterior, eliminating the need to insert devices into the conduit and avoiding geometric constraints that hinder optical methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If an array of pairs of temperature sensors is used to detect material deposits, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improvedeposit detection precisionVSAvoidsensor assembly complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor assembly divides the detection function into multiple discrete temperature sensors arranged in pairs along the conduit. Each pair measures temperature at specific locations, and by segmenting the measurement across multiple points, the system achieves precise localization and quantification of deposits without requiring a single complex sensor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The temperature sensor array serves multiple functions: detecting the presence of deposits, locating deposit positions along the conduit, and potentially quantifying deposit thickness. This multi-functionality reduces the need for separate detection systems while maintaining high measurement precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 sensor assembly effectively monitors and detects material deposits within fluid flow conduits, preventing clogs and ensuring accurate fluid flow by utilizing thermal response differences to determine deposit presence.

Implementation Method 1

detect material deposits by monitoring thermal responses

Methodology Applied

Scientific EffectThermal response: Conduction (thermal)

Implementation Method 2

a heater secured to an exterior portion of the body

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250180386A1Devices for detecting material deposits in fluid flow conduits

Publication Date: 2025.06.05 WATLOW ELECTRIC MANUFACTURING CO

AI summary

A fluid flow sensor assembly for detecting material deposits in a fluid flow conduit includes a body and an array of pairs of temperature sensors disposed within the body, where each pair of temperature sensors is spaced a distance apart along a primary flow direction of the fluid flow conduit.