MFC Strain Sensor Array for Low Velocity Fluid Flow Measurement
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Solution Overview
Problem
Existing fluid flow measurement technologies face challenges in accurately measuring low flow velocities and are prone to errors due to intrusive methods, reliability issues, and limitations in handling multiphase flows and pipe size constraints.
Innovation Solution
A fluid flow sensing apparatus using a sensor array with macro fiber composite (MFC) strain sensors mounted on the outer radial surface of a pipe, configured to detect pressure variations and aligned with the pipe's circumference, providing enhanced sensitivity and signal-to-noise ratio through compressive strain, allowing for accurate measurement of fluid flow parameters across various velocities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic time of flight or Doppler methods are used, then flow velocity can be measured, but measurement precision deteriorates at low flow velocities
Solution Approach 1:
The patent replaces conventional ultrasonic measurement methods with a mechanical strain sensing system. MFC (macro fiber composite) strain sensors are mounted on the pipe exterior to directly measure mechanical strain caused by fluid flow, bypassing the limitations of ultrasonic methods at low velocities. This mechanical substitution enables accurate measurement of low flow velocities where ultrasonic methods fail.
Solution Approach 2:
The patent changes the measurement parameter from ultrasonic time of flight or Doppler shift to mechanical strain. By mounting MFC strain sensors on the pipe exterior, the system measures strain variations that occur during fluid flow, providing a different physical basis for velocity measurement that is sensitive even at low flow rates.
2Measurement precision
If invasive probe insertion or pipe geometry changes are implemented, then fluid flow parameters can be measured, but reliability worsens due to clogging and process disruption
Solution Approach 1:
The patent extracts the sensing function from the fluid stream by mounting strain sensors on the exterior of the pipe. The MFC strain sensors measure pipe wall strain caused by internal fluid flow without any part of the measurement system contacting the fluid, eliminating clogging risks and process disruption while maintaining measurement capability.
Solution Approach 2:
The pipe wall itself serves as an intermediary medium that transmits the effects of internal fluid flow to external sensors. The MFC strain sensors mounted on the pipe exterior detect strain variations in the pipe wall, which are caused by the flowing fluid inside, providing indirect but reliable measurement without fluid contact.
3Measurement precision
If rotating wheels or moving parts are used, then flow measurement can be achieved, but reliability deteriorates due to mechanical wear and failure
Solution Approach 1:
The patent replaces rotating mechanical components with stationary strain sensors. Instead of using rotating wheels or moving parts to measure flow, the system uses MFC strain sensors that remain fixed on the pipe exterior, eliminating mechanical wear, lubrication requirements, and moving part failures while maintaining flow measurement capability.
4Measurement precision
If Coriolis meters are used, then mass flow rate can be measured, but adaptability worsens due to multiphase flow limitations and pipe size constraints
Solution Approach 1:
The patent creates a universal measurement system that can handle various flow conditions including multiphase flows. The MFC strain sensors measure pipe wall strain regardless of whether the internal flow is single-phase or multiphase, and the system adapts to different pipe sizes without requiring geometry changes, providing broad applicability across different flow scenarios.
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 apparatus effectively measures fluid flow parameters, including volumetric flow rate and mass flow rate, at low velocities and in multiphase flows, offering improved sensitivity and reliability compared to existing technologies.
Implementation Method 1
The at least one first MFC strain sensor and the at least one second MFC strain sensor are both configured to produce signals representative of pressure variations of the fluid flow passing within the pipe
Implementation Method 2
The sensing device is configured for attachment to the pipe outer radial surface so that the at least one first MFC strain sensor and the at least one second MFC strain sensor each have their respective first axis substantially aligned with the circumference of the pipe
Data Source
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AI summary
An apparatus for measuring a parameter of a fluid flow passing within a pipe is provided. The apparatus includes a sensing device and a processing unit. The sensing device has a sensor array that includes at least one first macro fiber composite (MFC) strain sensor disposed at a first axial position, and at least one second MFC strain sensor disposed at a second axial position. The first axial position and the second axial position are spaced apart from one another. The at least one first MFC strain sensor and the at least one second MFC strain sensor are both configured to produce signals representative of pressure variations of the fluid flow passing within the pipe. The processing unit is configured to receive the signals from the sensor array and measure one or more fluid flow parameters based on the signals.