Pressure Flow Control with Thermal Sensor Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pressure type flow control systems using orifices face challenges in maintaining accurate flow control and monitoring due to complexity in control unit configuration, reduced response characteristics, and difficulties in downsizing, as well as time-consuming and labor-intensive valve inspections for detecting anomalies.
Innovation Solution
A pressure type flow control system with integrated flow monitoring using a thermal type flow sensor, where the thermal type flow sensor is positioned downstream of the control valve, allowing for real-time flow monitoring and simplified control unit configuration, enabling precise flow control and swift anomaly detection without detaching valves from pipe passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thermal type flow sensor is integrated into the pressure type flow control system, then real-time flow monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent combines the thermal type flow sensor with the pressure type flow control system into an integrated unit. The flow sensor is positioned downstream of the control valve and merged with the existing control structure, allowing simultaneous pressure control and flow monitoring functions within a single device, thereby improving real-time monitoring capability while managing device complexity through organic integration.
2Device complexity
If the control unit configuration is simplified, then device complexity is reduced, but response characteristics deteriorate
Solution Approach 1:
The control unit is segmented into distinct functional modules: a flow control unit that manages pressure control valve operations and a flow monitoring unit that handles thermal sensor data processing. This segmentation allows each module to operate independently with optimized response characteristics, maintaining fast response speeds while presenting a simplified integrated interface that reduces overall device complexity.
3Device complexity
If the system is downsized, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The thermal type flow sensor is nested within the existing pressure control system structure, positioned downstream of the control valve in a compact arrangement. This nesting approach allows the monitoring function to be embedded within the control unit's existing footprint, achieving system downsizing without requiring separate external monitoring equipment, thereby reducing overall device complexity while maintaining manufacturing feasibility.
4Reliability
If valve inspections are performed frequently, then reliability is improved, but loss of time increases
Solution Approach 1:
The thermal type flow sensor enables continuous real-time monitoring of flow rates throughout system operation, replacing periodic manual valve inspections with uninterrupted automated monitoring. This continuous measurement approach maintains high reliability by detecting anomalies as they occur, while eliminating the time loss associated with frequent manual inspection interruptions.
Solution Approach 2:
The system performs self-diagnosis through the flow sensor's continuous monitoring capability, automatically detecting valve anomalies and flow deviations without requiring external inspection intervention. The system monitors its own operational parameters in real-time, enabling anomaly detection while eliminating the need for time-consuming manual valve inspections.
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 enables stable and precise pressure type flow control, continuous real-time monitoring, and efficient detection of valve anomalies, reducing the need for extensive inspections and improving gas replacement characteristics, thus enhancing operational efficiency and reducing downtime.
Implementation Method 1
a thermal type flow sensor 2 that is connected to a downstream side of the control valve 3
Data Source
AI summary
A pressure type flow control system with flow monitoring includes an inlet, a control valve including a pressure flow control unit connected downstream of the inlet, a thermal flow sensor connected downstream of the control valve, an orifice installed on a fluid passage communicatively connected downstream of the thermal flow sensor, a temperature sensor provided near the fluid passage between the control valve and orifice, a pressure sensor provided for the fluid passage between the control valve and orifice, an outlet communicatively connected to the orifice, and a control unit including a pressure type flow rate arithmetic and control unit receiving a pressure signal from the pressure sensor and a temperature signal from the temperature sensor, and a flow sensor control unit to which a flow rate signal from the thermal flow sensor is input.