Grid Sensor Tensioned Electrodes High Pressure
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Solution Overview
Problem
Existing grid sensors with wire electrodes are not suitable for high pressures and high temperatures, and they are difficult to exchange when damaged.
Innovation Solution
A compression-resistant grid sensor configuration using tensioned wire electrodes with insulation and mounting elements, including a spring suspension system and temperature-resistant materials, allows for reliable operation at high temperatures and pressures, with the ability to exchange electrodes when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wire electrodes are used in grid sensors, then measurement precision is improved, but reliability deteriorates under high pressure and high temperature conditions
Solution Approach 1:
The sensor is divided into modular components: electrode planes, insulation elements, and mounting structures. This segmentation allows each component to be optimized independently for high-temperature and high-pressure resistance while maintaining the overall measurement function.
Solution Approach 2:
The patent employs composite material structures combining temperature-resistant materials for the sensor body with electrical insulation elements and wire electrodes. This composite approach enables the sensor to withstand harsh environmental conditions while maintaining measurement precision.
2Measurement precision
If wire electrodes are tensioned in the conduit cross-section, then measurement capability is improved, but device complexity increases due to mounting and insulation requirements
Solution Approach 1:
The mounting structure serves multiple functions simultaneously: it provides mechanical support for the electrode wires, ensures proper tensioning, provides electrical insulation between electrodes and conduit wall, and facilitates easy replacement of electrode planes. This multi-functionality reduces overall device complexity.
Solution Approach 2:
Insulation elements are introduced as intermediary components between the wire electrodes and the conduit wall. These insulation elements simplify the overall structure by providing necessary electrical isolation without requiring complex mounting mechanisms.
3Productivity
If electrode planes are installed immediately behind one another, then productivity is improved, but reliability worsens due to difficulty in electrode exchange
Solution Approach 1:
The electrode planes are designed as separate, removable modules that can be independently replaced. This segmentation allows the sensor to maintain high installation efficiency while enabling easy exchange of electrode planes when damaged or worn.
Solution Approach 2:
The mounting structure incorporates dynamic elements that allow for easy removal and reinstallation of electrode planes. This dynamic design facilitates maintenance and repair operations while maintaining the compact arrangement of electrode planes.
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 solution enables accurate measurement of electroconductivity in high-pressure and high-temperature environments, maintaining sensor integrity and allowing for easy electrode replacement, thus overcoming the limitations of previous designs.
Implementation Method 1
Each individual wire (3) is placed under tension by means of a spring (2)
Implementation Method 2
the spring (2) is fixed inside of a channel that runs in the direction of tension of the wire in the sensor body (1) inside the pressure-conducting area of the sensor body (1). Moreover, each individual wire (3) is electrically insulated relative to its spring (2) by an insulating bead (4)
Implementation Method 3
they are conducted in insulating tubes (6)
Implementation Method 4
The voltages that occur on the electrodes of the second plane are compared to a threshold value. If the latter is exceeded, it is assumed that a conductive medium, e.g. liquid, is currently at the corresponding point of intersection for the electrodes of both planes
Data Source
AI summary
A grid sensor including grids of electrode wires for measuring the electroconductivity of flow medium in the cross-section of a pipeline is particularly suitable for applications where the flow medium flows at high pressure and high temperatures. Each of the electrode wires is connected to a spring via an insulating bead, the spring being arranged in a hole in a sensor body of the sensor having an axis which is oriented in a tensioning direction of the electrode wire, and fixed to the sensor body. Each of the electrode wires on the side opposing the spring is covered with an insulating tube arranged in an outwardly guided channel in the sensor body. The insulating tube ends inside the channel, in a cavity filled with a sealing material. Neither the insulating bead nor the insulating tube are located in the cross-section wherein the measurement is to be carried out.