Piezoelectric Load Cell Fluid Flow Sensor for Detonation Environments
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Solution Overview
Problem
Existing sensors fail to accurately measure and record fluid flow direction and velocity in hostile environments such as detonation events due to contamination and physical damage from debris, high temperatures, and the inability to resolve directionality, making them unsuitable for dynamic pressure conditions.
Innovation Solution
A high-survivability fluid flow sensor design featuring a sensor probe with piezoelectric load cells and a protective cap, which can withstand high-pressure detonations and debris, allowing for two-dimensional measurement of fluid flow direction and velocity by detecting loading on the probe through load cells and load transfer blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow measurement methods (hot-wire anemometry, pitot-tube) are used, then measurement capability is provided, but the sensors are susceptible to contamination from particulate matter and physical damage from debris impact
Solution Approach 1:
The sensor is divided into separate functional components: a robust housing structure, a protected sensing element, and a debris shield. The sensing element is isolated from direct exposure to the hostile flow field, allowing it to maintain measurement precision while the housing and shield absorb contaminants and debris impacts.
Solution Approach 2:
A protective housing and debris shield act as intermediaries between the flow field and the sensing element. These intermediary structures filter out particulate matter and deflect debris before they can reach the sensitive measurement components, resolving the contradiction between measurement capability and sensor survivability.
2Adaptability or versatility
If multi-hole pressure probes are used to provide flow directionality, then direction measurement capability is improved, but the system requires 5-7 pressure transducers and substantial calibration investment
Solution Approach 1:
The sensor housing is designed to perform multiple functions simultaneously: it protects the sensing element, defines the flow interaction geometry, and provides the structural framework for measurement. This multi-functionality reduces the need for separate calibration procedures and reduces overall system complexity while maintaining directionality measurement capability.
3Measurement precision
If sensors are exposed to the hostile flow field for direct measurement, then measurement accuracy is maintained, but the environment destroys sensors and produces zero visibility
Solution Approach 1:
The sensor employs a robust housing structure that acts as a protective shell, isolating the sensing elements from direct exposure to high-temperature gas flow and debris. The housing allows the sensor to withstand extreme environmental conditions while the protected sensing elements continue to provide accurate flow measurements.
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 and records fluid flow direction and velocity in extreme conditions, providing accurate data while surviving the harsh environment of detonation events, unlike traditional sensors which are prone to damage and contamination.
Implementation Method 1
A dynamic pressure induced fluid flow sensor is provided that includes a sensor housing defining an interior space, and a sensor cap disposed on the sensor housing and closing the interior space, the sensor cap having a probe port formed therein. A sensor probe has a first end mounted to the sensor housing and is disposed within the interior space. The sensor probe also includes a second end opposite the first end and extending away from the sensor cap outside the interior space where it is exposed to the fluid flow environment. At least one load cell is disposed within the interior space and is operatively engaged with the first end of the sensor probe. The load cell is configured to detect loading on the sensor probe as a result of fluid flow impinging on the exposed portion of the sensor probe adjacent to the second end.
Data Source
AI summary
A high survivability fluid flow sensor includes a sensor housing defining an interior space. A sensor probe has a first end disposed within the interior space. The sensor probe also includes a second end opposite the first end outside the interior space. At least one load cell is disposed within the interior space and is operatively engaged with the first end of the sensor probe. The load cell is configured to detect loading on the sensor probe as a result of fluid flow impinging on the sensor probe adjacent to the second end. The sensor is operable to capture fluid flow data history through an over pressure event via the sensor probe, which exerts pressure upon the piezoelectric load cell(s), thereby enabling analysis of the wave fluid dynamics.