Arrangement and method to sense flow using mechanical stress microsensors
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Solution Overview
Problem
Existing fluid flow control systems face challenges in accurately monitoring and controlling fluid flow through conduits or orifices due to inefficiencies in flow sensing technology, which can lead to inaccurate position information and potential damage to equipment.
Innovation Solution
A torque sensor module is integrated directly into the rotating shaft of a mechanical flow control assembly, utilizing MEMS sensors and wireless communication to measure fluid flow-induced rotational forces, generating accurate flow measurements and position information for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow sensors with multiple parts (differential pressure sensor elements, tubing, pickups) are used, then flow measurement capability is provided, but device complexity and installation cost increase due to multiple parts requiring assembly and wiring
Solution Approach 1:
The patent combines multiple flow sensing components (differential pressure sensor elements, tubing, pickups) into a single integrated flow sensor assembly. This merging of previously separate parts into one unified device reduces assembly complexity, minimizes wiring requirements, and simplifies installation while maintaining flow measurement capability.
2Reliability
If position information accuracy is insufficient, then control reliability is compromised, but equipment may be damaged due to inaccurate position feedback
Solution Approach 1:
The patent implements accurate position sensing with feedback to the control mechanism. The flow sensor assembly provides precise position information about the valve or damper, enabling the control system to accurately determine current state and make appropriate control decisions, thereby preventing equipment damage from incorrect positioning attempts.
3Measurement precision
If flow sensors with multiple components are installed, then flow monitoring is enabled, but installation time and labor cost increase
Solution Approach 1:
By integrating multiple sensing components into a single flow sensor assembly unit, the patent reduces the number of separate installation steps. The unified design allows for quicker installation with less wiring and assembly work compared to installing individual differential pressure sensor elements, tubing, and pickups separately.
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 risk of equipment damage and improving system efficiency by providing real-time feedback for optimal operation.
Implementation Method 1
The MEMs sensor device is operable to determine a fluid flow induced mechanical stress on a flow control device connective element
Implementation Method 2
The torque sensor measures torque in the rotating shaft of the damper assembly to measure fluid flow. Fluid flow through a mechanical flow control device causes a rotational force on the device
Data Source
AI summary
An arrangement for controlling flow includes a flow control element, an actuator, a linkage assembly, and a sensor module. The linkage assembly is coupled between the flow control element and the actuator, and includes a rotatable linkage element coupled to impart force to the flow control element. The sensor module is affixed to the rotatable linkage element. The sensor module includes a MEMs-based strain gauge affixed to a substrate and operably coupled to measure torque on the linkage element, and a processing circuit disposed on the substrate. The processing circuit is operably coupled to receive torque measurement information representative of the measured torque. The processing circuit generates a fluid flow measurement value based on the torque measurement information and position information representative of a position of a flow control device of the flow control element. The flow control device is mechanically coupled to the rotatable linkage element.