Multi-Gas Flow Sensor with Gas-Specific Calibration
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Solution Overview
Problem
Existing multi-gas flow sensors require complex systems and multiple sensors for accurate measurement, leading to increased processing time, installation costs, and inaccurate results due to limited sensing and signal conditioning capabilities.
Innovation Solution
A multi-gas flow sensor apparatus utilizing a combi sensor with gas-specific calibration capabilities, coupled with a conditioning microcontroller and signal conditioner, which processes and stores correction factors to linearize the relationship between flow rate and signal output, allowing for accurate measurement of multiple measurands in a single package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sensors with different addresses are used to measure multiple gases, then measurement capability is improved, but device complexity and installation costs increase
Solution Approach 1:
The patent combines multiple sensing capabilities into a single integrated flow sensor that can measure multiple gases simultaneously. The sensor integrates multiple measurand detection (flow rate and multiple gas concentrations) into one device, eliminating the need for multiple separate sensors and reducing system complexity while maintaining measurement versatility
Solution Approach 2:
The flow sensor is designed with universal multi-functionality to measure not only flow rate but also multiple gas types (e.g., O2, CO2, N2O, He, air) using a single sensor platform. This multi-functional approach allows one sensor to perform the work of multiple specialized sensors, reducing installation costs and simplifying the measurement system
2Device complexity
If a single sensor with complex system level calibration is used, then device complexity is reduced, but processing time increases and measurement accuracy decreases
Solution Approach 1:
The patent implements preliminary gas-specific calibration procedures during the manufacturing process, storing calibration factors in the sensor's memory. This preliminary calibration action eliminates the need for complex system-level calibration during installation and operation, reducing processing time while maintaining high measurement accuracy through pre-optimized calibration parameters
Solution Approach 2:
The patent replaces complex mechanical calibration systems with electronic calibration storage and processing. Calibration factors are stored in electronic memory and applied through digital signal processing, substituting complex mechanical adjustment systems with simpler electronic solutions that maintain precision while reducing processing time
3Adaptability or versatility
If multiple sensors are used for multi-gas measurement, then measurement versatility is improved, but installation costs and package size increase
Solution Approach 1:
The patent merges multiple gas sensing capabilities into a single integrated sensor package, reducing the number of components that need to be installed and connected. This consolidation lowers installation costs while maintaining the ability to measure multiple gases simultaneously
Solution Approach 2:
The sensor employs universal multi-functionality to detect multiple gas types through a single device platform, eliminating the need for multiple specialized sensors. This approach reduces both installation costs and package size while preserving measurement versatility across different gas applications
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 solution provides a cost-effective and compact multi-gas flow sensor system capable of accurately measuring various gases by linearizing the flow rate signal, reducing processing time and installation costs, and improving measurement accuracy.
Implementation Method 1
thermal transfer characteristics of the media being measured and the media of the transducer
Implementation Method 2
temperature coefficients of resistance with respect to the utilized sensing element
Implementation Method 3
The signal conditioner provides a high order calibration and signal processing of flow signals from the combi sensor to a processed signal output representative of the flow
Data Source
AI summary
A multi-gas/gas-mixture or liquid flow sensor apparatus utilizing a specific media calibration capability. The flow sensor can be coupled with an Application Specific Integrated Circuit (ASIC) that incorporates a signal conditioner and a memory module. The signal conditioner provides a high order calibration and signal processing of flow signals from the sensor to a processed signal output representative of the flow. The processed signal output can be stored in the memory module. A correction factor can be calculated and stored in the memory module in response to the stored values of the processed signal output, which tends to linearize the relationship between the flow rate and the processed signal output of a measuring system. The correction factor and/or the processed signal output provided by the signal conditioner can be utilized by the measuring system.