Measuring Channel Sensor Array Layout for Precise Flow Sensing
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Solution Overview
Problem
Existing measuring channels face challenges in achieving precise measurements of processing fluid parameters, particularly in complex geometries, due to disturbances caused by projecting sensor components and high manufacturing costs associated with precise alignment and tolerances.
Innovation Solution
A process for spatially arranging sensor components within measuring channels using a desired geometry model, allowing for precise positioning and orientation of sensor components relative to the actual channel geometry, thereby reducing manufacturing expenditure and improving measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor components project into the measuring channel to enable measurement, then measurement capability is achieved, but flow disturbance occurs and measurement precision deteriorates
Solution Approach 1:
The sensor components are extracted from the projecting configuration and integrated flush into the channel wall structure. The sensor housing is positioned within the channel wall thickness, with only the measurement opening exposed to the flow, eliminating the harmful projection into the flow path while preserving measurement capability.
Solution Approach 2:
The sensor housing is nested within the channel wall structure, utilizing the wall thickness to accommodate the sensor body. This nesting approach allows the sensor to be embedded in the wall rather than projecting outward, eliminating flow disturbance while maintaining measurement function.
2Measurement precision
If multiple sensor components are grouped in pairs or groups as interacting sensor arrays, then measurement functionality is enhanced, but positioning and orientation complexity increases
Solution Approach 1:
The desired geometry model is created in advance, containing all positioning and orienting parameters for multiple sensor components. This preliminary definition allows automated manufacturing processes to precisely position multiple sensors without requiring complex manual alignment during assembly.
Solution Approach 2:
Manual mechanical alignment and positioning of sensor arrays is replaced by automated manufacturing processes guided by the desired geometry model. The model serves as a digital blueprint that directs automated equipment to position sensors with high precision, eliminating the need for cumbersome manual adjustment.
3Measurement precision
If sensor components are manually assembled with precise positioning, then measurement accuracy is improved, but manufacturing time and cost increase
Solution Approach 1:
All positioning and orienting parameters are preliminarily defined in the desired geometry model before manufacturing. This allows automated processes to directly manufacture the final precise configuration without requiring subsequent manual adjustment, thereby improving manufacturing efficiency while maintaining measurement accuracy.
Solution Approach 2:
The desired geometry model serves as a digital copy or blueprint that accurately represents the final precise arrangement of sensor components. This digital model is used to guide automated manufacturing processes, ensuring that the physical assembly replicates the optimized configuration without manual intervention.
4Measurement precision
If high-tolerance manufacturing is used to achieve precise sensor positioning, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The desired geometry model preliminarily defines all positioning parameters, allowing standard manufacturing processes to produce components with acceptable tolerances. The precise final positioning is achieved through automated manufacturing guided by the model, eliminating the need for expensive high-tolerance manufacturing while maintaining measurement precision.
Solution Approach 2:
The approach changes the critical parameters from manufacturing tolerances to digital model precision. Instead of requiring expensive tight physical tolerances in manufacturing, the system uses a precise digital geometry model to guide automated positioning, achieving high precision at lower manufacturing cost.
Data Source
AI summary
In a method for spatially arranging at least one sensor array in a measuring channel, a predetermined desired geometry of the measuring channel is provided; a desired sensor-array arrangement associated with the desired geometry of the measuring channel is provided, where the sensor-array arrangement includes spatially-defined positioning parameters and orienting parameters in regard to the sensor components; an actual geometry of the measuring channel is captured; it is determined if a positioning parameter or an orienting parameter is outside of an admissible value range in relation to the actual geometry of the measuring channel, and the at least two sensor components of the sensor array are arranged in the measuring channel according to a most-current desired-sensor-array arrangement.