Viscometer System Using Optical Flow Cell for Online Viscosity
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Solution Overview
Problem
Existing methods for determining fluid viscosity are inefficient, require equipment downtime, and lack capability to accurately measure low flow rates, necessitating separate and costly viscometer systems that are not easily integrated with existing machinery.
Innovation Solution
A viscometer system utilizing an optical flow cell with a calibrated constriction and pressure sensors to calculate fluid viscosity based on flow rate and pressure changes, allowing for on-line measurement and integration with existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional viscosity measurement methods are used, then viscosity can be determined, but the machine must be taken off-line resulting in loss of productivity
Solution Approach 1:
The patent combines the viscosity measurement system with the existing optical flow cell used for debris analysis. The same flow cell and imaging system are utilized to track particles while adding pressure transducers to measure pressure differential. This merging eliminates the need for separate viscosity measurement equipment and allows simultaneous debris analysis and viscosity measurement during normal machine operation.
Solution Approach 2:
The optical flow cell is designed to serve multiple functions: it originally was used for debris analysis and now also performs viscosity measurement. By adding pressure transducers and using the existing particle tracking capability, the system achieves multi-functionality, allowing both debris monitoring and viscosity determination without requiring additional dedicated equipment.
2Measurement precision
If separate viscosity measurement systems are installed, then viscosity can be identified, but the system becomes bulky and costly
Solution Approach 1:
The patent merges the viscosity measurement capability into the existing optical flow cell system. Instead of installing a separate bulky viscometer, the system uses the same flow cell, imaging system, and controller, adding only pressure transducers to the existing configuration. This significantly reduces device complexity and cost while maintaining measurement accuracy.
Solution Approach 2:
The system achieves multi-functionality by using the optical flow cell for both debris analysis and viscosity measurement. The controller processes data for both purposes, and the imaging system serves dual functions, eliminating the need for separate dedicated viscosity measurement equipment and reducing overall system complexity.
3Measurement precision
If existing viscometers are used, then viscosity can be measured, but they cannot accurately determine viscosity at low fluid flow rates
Solution Approach 1:
The patent changes the measurement parameters by using pressure differential measurements combined with particle tracking at various flow rates. The system captures images at different time intervals and uses the calibrated constriction constant to calculate viscosity accurately across a wide range of flow rates, including low flow rates where traditional viscometers fail.
Solution Approach 2:
The system dynamically adjusts the imaging frequency and processing parameters based on the flow rate conditions. At low flow rates, the system increases the time interval between images and adjusts processing parameters to maintain measurement accuracy, allowing versatile operation across different flow conditions.
4Loss of information
If multiple separate systems are installed for debris analysis and viscosity measurement, then both parameters can be monitored, but operational costs increase
Solution Approach 1:
The patent combines debris analysis and viscosity measurement into a single integrated system using the same optical flow cell, imaging system, and controller. This eliminates the need for separate equipment, reduces operational costs, and prevents information loss by providing comprehensive fluid condition monitoring through one unified system.
Solution Approach 2:
The system achieves multi-functionality by simultaneously performing debris analysis and viscosity measurement using the same hardware resources. The controller processes both types of data, and the imaging system serves dual purposes, eliminating redundant equipment and reducing operational costs while maintaining complete fluid condition monitoring.
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
Enables efficient, accurate, and cost-effective measurement of fluid viscosity across a wide range of flow rates and temperatures, reducing downtime and operational costs by integrating with existing machinery.
Implementation Method 1
an optical flow cell with a calibrated constriction and pressure sensors to calculate fluid viscosity based on flow rate and pressure changes
Implementation Method 2
pressure sensors to calculate fluid viscosity based on flow rate and pressure changes
Data Source
AI summary
A viscometer system to determine the viscosity of a fluid utilizes an existing flow cell, which maintains a calibrated constriction that is defined by a predetermined constant value K is disclosed. The viscometer system is adapted for use with the flow cell and includes a pair of pressure transducers with one at the input of the flow cell and another at the outlet of the flow cell. During operation, particles within the fluid pass through the flow cell, whereby the positional change of the particles over a predetermined period of time allows the system to calculate the flow rate of the fluid. The system also identifies the change in pressure of the fluid as it passes through the flow cell, such that the pressure change, flow rate, and the constant value K are processed to calculate the viscosity of the fluid being analyzed.