Monolithic Flow Sensor Assembly for Stable Full-Pipe Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current insertion flow meters face inaccuracies due to varying flow profiles, require complex electrode shielding, are prone to rotation and deflection, and have costly installation processes, which affect their accuracy and reliability.
Innovation Solution
The sensor assembly features a scalable design with aligned electrodes spanning the pipe diameter, uses a combined snap-fit and threaded joint for secure installation, and employs AC coupling to eliminate DC offset, reducing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a threaded joint is used for installation, then the meter can be securely installed, but the sensor may rotate or back out after installation
Solution Approach 1:
The patent combines a snap-fit feature and a threaded feature into a single joint structure. The snap-fit portion prevents rotation and backing out, while the threaded portion provides secure attachment and allows for alignment adjustment during installation. This merged structure resolves the contradiction by providing both installation security and alignment stability simultaneously.
2Force
If a smaller stem is used, then the insertion force is reduced, but the stem becomes subject to deflection, vibration, and breakage
Solution Approach 1:
The stem is segmented into two distinct portions: a smaller-diameter first portion for insertion that requires less force, and a larger-diameter second portion for the sensor head that provides increased strength and resistance to deflection and vibration. This segmentation allows each portion to be optimized for its specific function, resolving the contradiction between insertion force and stem strength.
3Device complexity
If equal weightings are given to each sensor reading, then the measurement process is simplified, but accuracy deteriorates when flow varies from calibration conditions
Solution Approach 1:
The patent applies different weightings to different sensor readings based on their local characteristics and position within the flow profile. Rather than uniform weighting, each sensor's reading is weighted according to its specific contribution to accurate flow measurement under varying flow conditions. This local quality approach maintains measurement precision while the controller automatically adjusts weightings without requiring detailed flow profile information.
4Object-affected harmful factors
If electrode wires are shielded by running them up the middle of the core, then electromagnetic interference is reduced, but manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the electrode wires from the traditional path through the middle of the core and routes them through a separate channel or pathway in the sensor head assembly. This extraction allows the wires to be shielded from the electromagnetic field generated by the coils while avoiding the complex machining and assembly required to route wires through the core center, thereby reducing manufacturing complexity while maintaining electromagnetic interference protection.
5Ease of operation
If the meter is anchored at the top of the adapter, then installation is simplified, but excessive deflection and vibration occur due to the long moment arm
Solution Approach 1:
The patent changes the anchoring position from the top of the adapter (far from the flow force) to the bottom of the adapter (closer to the flow force). This dimensional change in the anchoring location reduces the moment arm length, thereby reducing deflection and vibration while maintaining installation simplicity through the same adapter interface.
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 design enhances measurement accuracy by incorporating a large sample area, minimizes electrode shielding complexity, and simplifies installation, resulting in improved performance and reduced costs.
Implementation Method 1
a sensor assembly that generates a magnetic field and measures the voltage induced in the conductive fluid flowing through the pipe
Implementation Method 2
The controller includes AC coupling circuitry to eliminate DC offset
Data Source
AI summary
A scalable monolithic sensor assembly, controller, and methods of making and installing same are disclosed. The sensor assembly includes a sensor head sized to fully traverse the diameter of the pipe such that its electrodes sample a voltage indicative of the entire pipe flow across its diameter. An improved stem design is included that decreases insertion force and increases lateral stability of the sensor head. An improved insertion device is disclosed that provide for independent axial insertion and rotation. An improved core is disclosed that minimizes interference of magnetic fields and reduces manufacturing costs. An improved controller is disclosed that improves sensitivity.