MEMS Torque Sensing for Accurate Flow Control Feedback
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Solution Overview
Problem
Existing fluid flow control systems face challenges in accurately monitoring and controlling fluid flow due to the complexity and cost of air flow sensors and water flow sensors, which often require multiple parts and wiring, leading to inefficiencies and potential damage from inaccurate position information.
Innovation Solution
A torque sensor module is coupled directly to the rotating shaft of a mechanical flow control assembly, utilizing MEMS sensors and wireless communication to measure fluid flow-induced rotational forces, generating flow measurements based on torque and position information, thereby providing accurate feedback for control mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional air flow sensors and water flow sensors are used to measure fluid flow, then flow measurement capability is achieved, but device complexity and cost increase due to requiring multiple parts and wiring
Solution Approach 1:
The patent combines the flow measurement function with the existing position sensor by integrating a torque sensor into the actuator assembly. This merging eliminates the need for separate flow sensors and their associated wiring, reducing device complexity while maintaining measurement capability. The torque sensor utilizes the existing mechanical linkage between the actuator and flow control element to derive flow information from torque measurements.
Solution Approach 2:
The actuator assembly is designed to perform multiple functions: it controls the position of the flow control element and simultaneously measures flow through the integrated torque sensor. This multi-functionality eliminates the need for dedicated flow sensing components, reducing overall system complexity while achieving accurate flow measurement through the relationship between torque, position, and flow rate.
2Measurement precision
If traditional flow sensors with multiple parts are used, then flow measurement is achieved, but manufacturing cost and installation labor increase
Solution Approach 1:
The flow measurement capability is merged into the actuator assembly through integration of the torque sensor. This eliminates the need for separate flow sensor components and their associated wiring harnesses, significantly reducing installation complexity and labor requirements while maintaining accurate flow measurement capability.
Solution Approach 2:
The system utilizes its own existing mechanical components (actuator, shaft, and linkage to the flow control element) to perform flow measurement. The torque sensor leverages the natural mechanical interaction between the actuator and flow control element during operation, eliminating the need for external flow sensing hardware and simplifying both manufacturing and installation.
3Ease of operation
If position information is inaccurate in flow control systems, then control functionality is maintained, but equipment damage may occur from incorrect positioning commands
Solution Approach 1:
The integrated torque sensor provides real-time feedback on the actual mechanical load and position of the flow control element. This feedback mechanism allows the control system to detect discrepancies between commanded and actual positions, and to identify when the element is fully open or closed, preventing damage from attempting to move beyond mechanical limits.
Solution Approach 2:
The system replaces purely mechanical position indication with electronic sensing through the torque sensor, which provides precise digital feedback on the actual position and mechanical state of the flow control element. This substitution eliminates the reliance on potentially inaccurate mechanical position indicators and provides reliable data for safe operation.
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
This solution enables precise control of fluid flow by accurately measuring torque and position, reducing the need for complex sensor setups and minimizing the risk of equipment damage from inaccurate positioning, while also simplifying installation and reducing costs.
Implementation Method 1
A sensor module includes a MEMs sensor device and a processing circuit. The MEMs sensor device is operable to determine a fluid flow induced mechanical stress on a first flow control device connective element.
Implementation Method 2
A torque sensor module is coupled directly to the rotating shaft of a mechanical flow control assembly, utilizing MEMS sensors and wireless communication to measure fluid flow-induced rotational forces
Data Source
AI summary
A sensor module includes a MEMs sensor device and a processing circuit. The MEMs sensor device is operable to determine a fluid flow induced mechanical force on a first flow control device connective element. The processing circuit is operably coupled to receive fluid flow induced mechanical force information based on the determined fluid flow induced mechanical force. The processing circuit is configured to generate a fluid flow measurement value based on the fluid flow induced mechanical force information and position information representative of a position of a flow control device coupled to the first flow control connective element.