Modular Flow Sensor With Interchangeable End Adapters
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Solution Overview
Problem
Existing flow sensors lack flexibility in accommodating diverse application requirements, limiting their adaptability and usability across various systems such as ventilators, respirators, and industrial processes.
Innovation Solution
A modular flow sensing assembly with interchangeable end adapters, allowing for customization of the main sense element assembly and sensor body to match specific application needs, featuring a main housing with interchangeable first and second end adapters that can be made from various materials and manufacturing processes, and equipped with fins to reduce turbulence and enhance flow consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flow sensors are designed with fixed configurations, then manufacturing and calibration are simplified, but adaptability to different applications is reduced
Solution Approach 1:
The flow sensor is divided into modular components: a main body housing containing the sensing elements and interchangeable end adapters that can be attached to different ports. This segmentation allows the core sensing mechanism to remain simple while adapting to various applications through adapter selection, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The main body housing is designed as a universal platform that can work with multiple types of end adapters (e.g., different port sizes, thread types, or connection methods). This multi-functionality enables a single sensor design to serve diverse applications without requiring complex reconfiguration of the sensing elements themselves.
2Adaptability or versatility
If end adapters are made from various materials and processes, then customization for specific applications is improved, but manufacturing complexity increases
Solution Approach 1:
By separating the end adapters from the main sensing body, the patent allows adapters to be manufactured independently using materials and processes optimized for their specific requirements (e.g., medical-grade materials for respiratory applications, corrosion-resistant materials for industrial use). This segmentation maintains ease of manufacture for the core sensor while enabling customization through adapter selection.
Solution Approach 2:
The end adapters can be designed as lower-cost, application-specific components that are easier to manufacture and replace than the main sensing body. This approach allows customization for different applications without requiring expensive modifications to the core sensor, maintaining ease of manufacture while improving adaptability.
3Measurement precision
If fins are added to reduce turbulence, then flow measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The fins are strategically positioned only in specific regions where turbulence would most affect measurement accuracy (e.g., near the sensing elements or in high-velocity zones). This localized approach improves flow measurement accuracy without adding fins throughout the entire device, thereby minimizing the increase in device complexity.
Solution Approach 2:
The fins are integrated into the existing structure of the end adapters or housing rather than being separate components. This merging of functions allows the fins to perform their turbulence-reducing function while utilizing existing structural elements, thus improving measurement accuracy without proportionally increasing device complexity.
Data Source
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AI summary
The present disclosure relates to modular flow sensor assemblies and methods. The modular flow sensor assembly may include a main sensor body, a first end adapter having a first connection port configuration, and a second end adapter having a second connection port configuration. The main sensor body may include a main housing and a sensor, where the first end adapter is configured to engage the main housing and the second end adapter is configured to engage the main housing. The first end adapter and the second end adapter may be selected from a group of end adapters, wherein at least two of the end adapters has a different connection port configuration. The selected first end adapter and the selected second end adapters may have the same or different connection port configurations. The first end adapter and the second end adapter are configured to be interchangeable end adapters.