Plug-in Sensor Airfoil Profile for Contamination and Pressure Drop
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Solution Overview
Problem
Existing plug-in sensors for measuring fluid parameters in flow tubes, such as hot-film air-mass meters, face issues with contamination and aerodynamically unfavorable designs that lead to pressure drops and unsatisfactory signal reproducibility due to their construction and flow patterns.
Innovation Solution
The design optimizes the arrangement and positioning of outlet openings using airfoil profiles with asymmetrical flow profiles and strategically placed pressure minimums to enhance throughput and minimize contamination, incorporating flow guidance elements to reduce turbulence and improve signal characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a plug-in sensor is used with a bypass duct to prevent contamination, then contamination resistance is improved, but pressure drop increases due to aerodynamically unfavorable shape
Solution Approach 1:
The plug part is designed with an airfoil profile that creates asymmetrical flow patterns, generating a low-pressure zone on the suction side that enhances contamination resistance while optimizing pressure characteristics
Solution Approach 2:
The airfoil profile introduces curved surfaces that optimize flow attachment and reduce turbulence, improving aerodynamic performance while maintaining contamination protection
2Object-affected harmful factors
If a plug-in sensor with bypass duct is used, then contamination resistance is improved, but signal reproducibility deteriorates due to flow disturbances
Solution Approach 1:
The asymmetrical airfoil profile creates a low-pressure zone that stabilizes flow patterns and reduces turbulence-induced signal variations, improving reproducibility while maintaining contamination protection
Solution Approach 2:
The flow disturbances that previously degraded signal quality are converted into beneficial low-pressure zones that stabilize flow and improve measurement reproducibility
3Ease of manufacture
If outlet opening is positioned at conventional locations, then manufacturing is simpler, but throughput is reduced due to unfavorable pressure distribution
Solution Approach 1:
The outlet opening is positioned specifically on the suction side where the airfoil profile creates a local low-pressure zone, optimizing throughput while remaining manufacturable
Solution Approach 2:
Positioning the outlet opening at a specific location on the suction side changes the pressure parameter at the outlet, creating a pressure difference that enhances air mass throughput
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
This configuration significantly improves air mass throughput, reduces pressure drops, and enhances signal reproducibility by minimizing flow disturbances and pulsation errors, resulting in a more stable and accurate measurement.
Implementation Method 1
The plug part has an airfoil profile which is designed in such a way that when the plug part is introduced into the flowing fluid medium, an asymmetrical flow profile of the fluid medium with a high-pressure side and a low-pressure side is set
Implementation Method 2
at least one outlet opening is arranged on the side of the plug part in the area of this at least one pressure minimum
Implementation Method 3
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
Implementation Method 4
At least one heating resistor, which is surrounded by two or more temperature measuring resistors (temperature sensors), is typically arranged on the sensor membrane
Implementation Method 5
at least one flow guidance element which integrates the outflowing fluid into the surrounding flow around the plug part, as a result of which this flow is disturbed as little as possible
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
The invention proposes a plug-in sensor (110), which is suitable for determining at least one parameter of a fluid medium flowing in a main flow direction (126), particularly an intake air mass of an internal combustion engine flowing through a flow pipe. The plug-in sensor (110) has a plug part (116) that can be introduced into the fluid medium flowing in a predetermined orientation to the main flow direction (126). At least one flow channel (124) having at least one inlet orifice (128) and at least one outlet orifice (132, 138) is provided in the plug part (116), wherein at least one sensor (144) is received in the at least one flow channel (124) for determining the at least one parameter. The plug part (116) has a profile at which a minimum of at least one local minimum pressure (522) develops in the flowing fluid medium. The at least one outlet orifice (132, 138) is disposed on the side of the plug part (116) in the region of the at least one minimum pressure (522).