Mist Flow Rate Measurement via Luminance Correlation
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Solution Overview
Problem
Conventional methods for measuring the flow rate of raw material mist in mist-containing gases are indirect and prone to estimation errors due to time lags and deviations in atomization efficiency, leading to inaccurate measurements.
Innovation Solution
A mist flow rate measuring apparatus that uses a mist imaging camera to acquire imaging information of the mist flowing region and a mist flow rate calculation unit to derive the flow rate based on luminance values, employing a correlation parameter to accurately calculate the mist flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If indirect measurement methods (measuring raw material solution consumption) are used to determine mist flow rate, then the measurement process is simple, but the measurement precision deteriorates due to time lags and atomization efficiency deviations
Solution Approach 1:
The patent replaces indirect mechanical measurement (solution consumption) with direct optical detection (luminance measurement). The imaging camera captures luminance values of the mist-containing gas, and the calculation unit derives flow rate from these optical parameters, eliminating time lags and atomization efficiency deviations that plague mechanical measurement systems.
Solution Approach 2:
The patent introduces luminance values as an intermediary parameter between the mist flow and measurement. Instead of directly measuring solution consumption or mist flow, the system measures luminance intensity which correlates with mist concentration and flow rate, providing a real-time indirect indicator that resolves the timing and efficiency issues of direct measurement.
2Device complexity
If indirect measurement through raw material solution consumption is used, then the device structure remains simple, but the reliability deteriorates due to estimation errors
Solution Approach 1:
The patent substitutes the mechanical measurement system (flow meters, level sensors) with an optical measurement system (imaging camera). This replacement maintains structural simplicity while dramatically improving reliability by directly observing mist flow characteristics through luminance variations, eliminating estimation errors inherent in indirect mechanical measurement.
Solution Approach 2:
The patent changes the measurement parameter from solution consumption volume to mist luminance intensity. This parameter transformation enables real-time flow rate determination with higher reliability, as luminance directly reflects mist concentration and flow conditions without the time delays and efficiency variations affecting solution-based measurements.
3Measurement precision
If direct imaging measurement of mist is implemented, then measurement precision improves, but device complexity increases due to additional imaging equipment
Solution Approach 1:
The patent makes the imaging camera multi-functional by using it both for quality inspection of the mist and for flow rate measurement. The same optical system that monitors mist formation quality also captures luminance data for flow calculation, eliminating the need for separate measurement devices and reducing overall system complexity despite the added imaging capability.
Solution Approach 2:
The patent repurposes optical imaging parameters (luminance values) traditionally used for quality assessment to also serve flow rate measurement. By extracting flow information from existing imaging data through calculation algorithms, the system achieves precise measurement without adding dedicated measurement hardware, thus limiting complexity increase.
4Ease of operation
If conventional indirect measurement is used, then the system is easy to operate, but measurement accuracy deteriorates due to time lag between solution supply and mist generation
Solution Approach 1:
The patent replaces the mechanical solution supply measurement system with an optical imaging system that directly observes mist flow. This substitution eliminates the time lag between solution supply and mist generation because the imaging camera captures real-time luminance data of the actual mist flow, providing immediate and accurate flow rate information without operational complexity.
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 accurately measures the flow rate of raw material mist by correlating luminance values with flow rates, minimizing estimation errors and stabilizing mist flow rates over time.
Implementation Method 1
imaging information which indicates a plurality of luminance values in a plurality of pixels
Implementation Method 2
imaging processing with at least a part of a mist flowing region through which a mist-containing gas containing a raw material mist flows set as an imaging target region
Implementation Method 3
when the ultrasonic transducer 2 executes ultrasonic vibration processing for applying ultrasonic vibration, vibration energy of the ultrasonic wave is transmitted to the raw material solution 15
Data Source
AI summary
In a mist flow rate measuring apparatus of the present disclosure, in a transparent pipe, a camera executes imaging processing of reflected light, the imaging processing having at least a part of a mist flowing region through which a mist-containing gas flows set as an imaging target region, and acquires imaging information. A mist flow rate calculation unit executes mist flow rate calculation processing based on the imaging information. The mist flow rate calculation processing includes sum value calculation processing of obtaining a luminance sum value, which is a sum of a plurality of luminance values indicated by the imaging information, and flow rate derivation processing of deriving the flow rate of the raw material mist from the luminance sum value.