Plug-in Sensor Airfoil Profile for Flow Dynamics
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Solution Overview
Problem
Existing sensors for measuring fluid parameters in flow tubes, such as hot-film air-mass meters, face contamination issues which lead to measurement inaccuracies and require complex constructions to mitigate, resulting in increased costs and flow resistance.
Innovation Solution
A compact plug-in sensor design with an airfoil profile that creates an asymmetrical flow, utilizing hydrodynamic principles to increase flow speed and reduce pressure drop, and a detachment element to stabilize flow separation, eliminating the need for additional flow calming components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a plug-in sensor is used with a bypass channel branching off at a sharp edge, then contamination of the sensor element is reduced, but pressure drop and flow resistance increase
Solution Approach 1:
The plug part is designed with an airfoil profile that creates asymmetrical flow patterns. The airfoil shape generates a low-pressure zone on the upstream side and a high-pressure zone on the downstream side, which actively pushes contaminants away from the sensor while maintaining smooth flow dynamics and reducing pressure drop compared to sharp-edged designs
Solution Approach 2:
The invention utilizes fluid dynamic principles by designing the airfoil profile to create pressure differential zones. The low-pressure zone on the upstream side acts as a suction effect to draw contaminants away from the sensor, while the high-pressure zone on the downstream side pushes them along the flow path, eliminating the need for sharp edges and reducing flow resistance
2Reliability
If additional flow deflector parts and flow baffles are permanently installed in the flow tube, then signal reproducibility is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The flow deflector function is merged directly into the plug-in sensor body through the airfoil profile design. The airfoil shape itself creates the necessary flow deflection and calming effects without requiring separate flow deflector parts or baffles to be permanently installed in the flow tube, thereby simplifying the overall system while maintaining signal reproducibility
Solution Approach 2:
The plug-in sensor is designed to be self-sufficient with the airfoil profile providing inherent flow management capabilities. The airfoil shape automatically creates low and high pressure zones that manage flow separation and stabilization without requiring external flow baffles or deflector parts, making the sensor self-contained and easier to install
3Device complexity
If a one-piece configuration of flow deflector part with plug-in sensor is used, then device complexity is reduced, but installation length becomes too long for many applications
Solution Approach 1:
The invention separates the flow management function (airfoil profile) from the sensor housing, allowing the airfoil to be integrated into the plug part without requiring a separate flow deflector component. This segmentation enables a more compact overall design that maintains simplicity while reducing installation length requirements
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 design enhances signal reproducibility and reduces pressure drop while maintaining low drag, improving the sensor's functionality and reducing installation complexity and costs.
Implementation Method 1
the plug part at least partially has an airfoil profile which is designed in such a way that an asymmetrical flow of the fluid medium occurs when the plug part is introduced into the flowing fluid medium
Implementation Method 2
The airfoil profile is preferably designed such that when the plug part is introduced into the flowing fluid medium, a flow profile is set in the fluid medium in which the speed of the flowing fluid medium is higher on the outlet side than on the opposite side. This increase in the flow rate in the area of the at least one outlet opening can increase the throughput through the at least one flow channel due to the hydrodynamic suction effect
Implementation Method 3
The plug part has a rounded inflow side, the rounded inflow side being integrated into the plug part, so that no additional configurations of the flow tube are required
Implementation Method 4
The temperature distribution changes in an air flow that is guided over the membrane, which in turn can be detected by the temperature measuring resistors and can be evaluated by means of a control and evaluation circuit
Implementation Method 5
At least one heating resistor, which is surrounded by two or more temperature measuring resistors (temperature sensors), is typically arranged on the sensor membrane
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
The invention relates to a plug-in sensor (110) for determining at least one parameter of a fluid medium flowing in a main flow direction (126), especially a suction air mass of an internal combustion engine, flowing through a flow tube. The plug-in sensor (110) comprises a plug-in part (116) which can be introduced into the flowing fluid medium in a pre-defined orientation in relation to the main flow direction (126). The plug-in part (116) is provided with at least one flow channel (124) comprising at least one inlet (128) and at least one outlet (610). At least one sensor (144) for determining the at least one parameter is received in the at least one flow channel (124). The plug-in part (116) comprises a rounded approach flow side (148) which is oriented away from the main flow direction. The at least one main flow channel (124) has at least one inlet (128) in the region of the rounded approach flow side (148). The plug-in part (116) at least partially has a carrier surface profile (210) which is designed in such a way that the fluid medium has an asymmetrical flow profile when the plug-in part (116) is introduced into the flowing fluid medium.