Multi-Cam Fluid Flow Sensor Linearization
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Solution Overview
Problem
Conventional fluid flow sensors struggle to accurately measure flow rates in turbulent flows within confined channels and pipes, as they require extended linear channels, only cover a portion of the flow stream's cross-section, and have a non-linear relationship between flow velocity and sensor movement, leading to decreased accuracy at higher velocities.
Innovation Solution
A multi-obstruction fluid flow sensor design that includes a plurality of cams, an obstruction member coupled to a first cam, an arcuate appendage coupled to a second cam, and a torsion spring, which converts the rotation of the obstruction member into a linearized rotation of the arcuate appendage, enabling accurate measurement of fluid velocity over a range of velocities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mechanical fluid flow sensors are used to measure flow rate, then the sensor structure is simple, but the measurement precision decreases at higher velocities due to non-linear relationship between flow velocity and sensor movement
Solution Approach 1:
The patent changes the geometric parameters of the obstruction member and cam profiles to create a specific non-linear relationship between flow velocity and cam rotation. This allows the mechanism to compensate for the non-linear response of conventional sensors, improving measurement precision across a wide velocity range while maintaining mechanical simplicity
Solution Approach 2:
The cam mechanism acts as an intermediary between the obstruction member and the sensor. It transforms the non-linear flow velocity into a linear rotational movement of the indicator, enabling accurate measurement without requiring complex electronic processing or additional sensors
2Measurement precision
If conventional sensors only cover a portion of the cross-section to avoid affecting flow velocity, then the flow stream is not disturbed, but the measurement precision is insufficient because turbulent portions and wall regions are not included
Solution Approach 1:
The obstruction member is segmented into multiple sections that extend across different portions of the flow stream cross-section. This allows the sensor to sample velocity information from multiple regions (including turbulent portions and wall regions) simultaneously, improving measurement precision without creating a single large disturbance
Solution Approach 2:
The obstruction member extends in the radial dimension across the flow stream cross-section, allowing it to interact with multiple flow velocity profiles simultaneously. This dimensional approach enables comprehensive flow measurement while distributing the disturbance across multiple small sections rather than concentrating it in one location
3Measurement precision
If conventional sensors require extended linear channels or straight pipes for accurate measurement, then the measurement precision may be improved, but the ease of operation decreases due to installation difficulty in existing plumbing systems
Solution Approach 1:
The sensor is designed with a flexible mounting mechanism that allows it to adapt to curved and irregular pipe surfaces. The obstruction member can dynamically adjust its position within the flow stream to maintain optimal measurement conditions, enabling accurate measurements in existing plumbing systems without requiring extended linear channels or straight pipes
Solution Approach 2:
The sensor design incorporates a universal mounting system that can be installed on various pipe types, sizes, and configurations (including curved pipes). This multi-functional capability allows the sensor to maintain measurement precision across different installation scenarios without requiring specific pipe conditions, greatly improving ease of operation
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 sensor effectively measures fluid velocity in turbulent flows and linearizes the rotation of the arcuate appendage over a range of fluid velocities, improving accuracy and reliability compared to conventional sensors.
Implementation Method 1
a plurality of cams, an obstruction member coupled to a first cam in the plurality of cams, wherein the obstruction member may be configured to rotate about the first cam relative to the fluid velocity
Implementation Method 2
a torsion spring coupled at least one of the plurality of cams, wherein the plurality of cams may be configured to convert a rotation of the obstruction member into a rotation of the arcuate appendage
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A method and device for accurately monitoring, displaying, and remote reporting of turbulent material flow streams in confined channels and pipes is provided. The device can have multiple cams coupled to an obstruction, and a spring. The multiple cams can have a cam profile, and the cam profile and the spring may be selected to linearize a rotation of the obstruction over a range of fluid flow velocities. The obstruction can include have multiple obstructions each in a different area of a cross-section of a pipe, improving the accuracy of the device.