Four-Tube Vibration Sensor for High Mass Flow
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Solution Overview
Problem
Conventional vibration-type measuring sensors face challenges in achieving high sensitivity and low pressure loss at high mass flow rates, especially above 2200 t/h, with large nominal diameters, and are prone to deformation and increased empty mass due to mechanical load requirements, making them unsuitable for large pipeline calibers and high-flow applications.
Innovation Solution
A vibration-type measuring system with four straight measuring tubes arranged in parallel, connected through flow dividers, which allows for optimal space utilization and reduced pressure loss, featuring a compact design with a low empty weight, and incorporates a deformation measuring arrangement to correct for stress changes caused by temperature or external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional vibration-type measuring sensors are designed for large nominal diameters and high mass flow rates, then they can handle larger pipeline calibers, but the sensor becomes prone to deformation and experiences increased empty mass due to mechanical load requirements
Solution Approach 1:
The sensor is divided into multiple measuring tubes (typically four) arranged in parallel, each handling a portion of the total flow. This segmentation allows each tube to be optimized for lower individual loads while collectively measuring high mass flow rates, reducing the empty mass compared to a single large-diameter sensor design.
Solution Approach 2:
The invention transitions from a single large-diameter measuring tube to multiple smaller tubes arranged in a multi-dimensional parallel configuration. This dimensional change enables the sensor to handle large flow rates through increased surface area and parallel flow paths without requiring excessive mechanical strength in individual components, thereby reducing overall empty mass.
2Strength
If conventional sensors are designed with thick-walled cylindrical tube segments to withstand mechanical loads, then strength is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The housing structure is segmented into multiple sections that accommodate individual measuring tubes, allowing each section to be optimized for its specific mechanical requirements rather than requiring a single thick-walled structure throughout. This reduces overall device complexity while maintaining necessary strength.
Solution Approach 2:
Different parts of the sensor housing have different wall thicknesses and structural characteristics tailored to their specific functional requirements. Areas subject to higher mechanical loads have enhanced strength, while other areas use thinner walls to reduce complexity and weight, achieving optimal strength-to-complexity ratio.
3Quantity of substance
If conventional sensors are designed for high mass flow rates above 2200 t/h, then they can handle industrial-scale flows, but measurement precision and sensitivity decrease due to deformation under mechanical load
Solution Approach 1:
By dividing the flow measurement into multiple parallel measuring tubes, each tube operates under lower mechanical stress and deformation, maintaining measurement precision. The individual measurements from all tubes are combined to provide accurate total flow measurement even at high mass flow rates above 2200 t/h.
Solution Approach 2:
The sensor incorporates measurement of vibration characteristics and mechanical deformation as feedback signals. This feedback is used to compensate for and correct measurement errors caused by mechanical loads, maintaining high measurement precision under high flow conditions through active correction algorithms.
4Area of stationary object
If conventional sensors use two flow-technically parallel measuring tubes, then space utilization is limited, but adding more tubes increases the number of components and device complexity
Solution Approach 1:
Multiple measuring tubes are merged into a single integrated sensor housing with common flow dividers and measurement electronics. This merging approach maximizes space utilization within the housing while minimizing the number of separate components and connections required, reducing overall device complexity despite having more than two measuring tubes.
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 achieves high measurement accuracy and sensitivity with minimal pressure loss, even at very high mass flow rates, and is suitable for large pipeline calibers, while maintaining manageable geometric dimensions and reducing production costs.
Implementation Method 1
They generate reaction forces in the medium, such as Coriolis forces corresponding to the mass flow rate
Implementation Method 2
They generate reaction forces in the medium, such as Coriolis forces corresponding to the mass flow rate, inertial forces corresponding to the density of the medium
Implementation Method 3
They generate reaction forces in the medium, such as Coriolis forces corresponding to the mass flow rate, inertial forces corresponding to the density of the medium, and/or frictional forces corresponding to the viscosity of the medium
Implementation Method 4
This vibration is driven by an excitation arrangement that serves to generate or maintain mechanical vibrations, especially bending vibrations, in the measuring tubes
Data Source
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Figure 3a
AI summary
The invention relates to a measurement system for measuring the density and/or mass flow rate of a medium flowing at least intermittently in a pipeline. The measurement system comprises a vibration-type measurement sensor for generating vibratory measurement signals and transducer electronics, which are electrically coupled to the measurement sensor, intended to actuate the measurement sensor and to analyze vibration measurement signals provided by the measuring transducer. The measurement sensor comprises a sensor housing (71) by which an inlet housing end is formed by means of an inlet side flow divider (201) comprising exactly four flow openings (201A, 201B, 201C, 201D) spaced apart from each other and an outlet housing end is formed by means of an outlet side flow divider (202) comprising exactly four flow openings (202A, 202B, 202C, 202D) spaced apart from each other, exactly four measurement tubes (181, 182, 183, 184) connected to the flow dividers (201, 202) and forming flow paths fluidically connected in parallel for carrying flowing medium, an electromechanical exciter arrangement (5) formed by means of a first vibrational exciter (51) for generating and/or maintaining mechanical vibrations of the four measurement tubes (181, 182, 183, 184), and a vibration sensor arrangement (19) reacting to vibrations of the measurement tubes (181, 182, 183, 184) for generating vibrational signals representing vibrations of the measurement tubes (181, 182, 183, 184). The transducer electronics in turn comprise a driver circuit for the exciter arrangement and a measurement circuit generating a measured density value representing the density of the medium by using at least one of the vibration measurement signals provided by the vibration sensor arrangement and/or a measured mass flow value representing the mass flow value. In order to generate the measured density value and/or the measured mass flow value, the measurement circuit of the measurement system according to the invention corrects a change of at least one characteristic parameter of the measured vibration signals provided by the measuring transducer. Said changes can also be caused by a change of a voltage condition in the measurement sensor and/or a deviation of a momentary voltage condition in the measurement sensor from a reference voltage condition prescribed therefor.