Robust Ultrasonic Flow Sensor Controller With Online Calibration
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Solution Overview
Problem
Existing flow meters face challenges in measurement precision, reliability, and functional safety, necessitating frequent recalibration and maintenance, which increases operational costs and downtime.
Innovation Solution
The implementation of a sensor controller with a transmitter, receiver, time-of-flight circuit, and phase shift circuit, along with control logic, to enhance measurement accuracy and reliability by swapping ultrasonic transducer roles, measuring phase shifts, and integrating online calibration and fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow meters are used, then basic flow measurement function is provided, but measurement precision and reliability are insufficient requiring frequent recalibration and maintenance
Solution Approach 1:
The patent divides the measurement system into multiple independent transducers (first ultrasonic transducer and second ultrasonic transducer) that can operate independently. Each transducer can measure flow rate separately, and the controller selects from multiple measurements to provide the final reading, improving both precision and reliability by eliminating dependency on a single component.
Solution Approach 2:
The patent implements online calibration functionality where the system uses the measured flow rates to verify and adjust calibration parameters in real-time. The controller compares measurements from different transducers and can automatically compensate for drift or changes in performance, maintaining high measurement precision without requiring frequent manual recalibration.
2Reliability
If redundant safety checks and online calibration functions are added, then functional safety is improved, but device complexity increases
Solution Approach 1:
The patent designs the controller to perform multiple functions using the same hardware resources. The controller manages both transducers for differential flow measurement, performs online calibration using the same transducers, and provides fault detection using the existing measurement infrastructure. This multi-functionality achieves high functional safety without proportionally increasing hardware complexity.
Solution Approach 2:
The system performs self-diagnosis and self-calibration using its own measurement capabilities. The controller automatically compares measurements from both transducers to detect faults and performs calibration adjustments without external intervention. This self-service approach improves functional safety while avoiding the need for additional complex external monitoring systems.
3Measurement precision
If multiple transducers and measurement systems are implemented, then measurement precision is improved through redundancy, but component costs and maintenance needs increase
Solution Approach 1:
The patent uses two relatively simple ultrasonic transducers instead of one complex high-precision transducer. Each transducer is identical and can be manufactured using standard processes, reducing individual component cost. The redundancy allows the system to tolerate failures in individual components while maintaining measurement capability.
Solution Approach 2:
The system can discard measurements from individual transducers when they fail or drift, relying on the other transducer's data. This fault tolerance reduces the need for expensive replacement components and simplifies maintenance, as the system can continue operating with reduced functionality rather than requiring complete system replacement.
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 approach improves measurement precision, reduces maintenance needs, and enhances operational safety by providing robust flow rate and level measurements while reducing costs.
Implementation Method 1
The transmitter is configured to provide a drive signal to an ultrasonic sending transducer to generate an acoustic burst
Implementation Method 2
The receiver is configured to receive a response signal from an ultrasonic receiving transducer
Implementation Method 3
The time-of-flight circuit is configured to detect an arrival of the acoustic burst in the response signal and to measure a first time of flight associated with that arrival
Data Source
AI summary
An illustrative sensor controller includes: a transmitter, a receiver, a time-of-flight circuit, and a phase shift circuit. The transmitter is configured to provide a drive signal to an ultrasonic sending transducer to generate an acoustic burst. The receiver is configured to receive a response signal from an ultrasonic receiving transducer. The time-of-flight circuit is configured to detect an arrival of the acoustic burst in the response signal and to measure a first time of flight associated with that arrival. The phase shift circuit is configured to measure a phase shift of the acoustic burst in the response signal and to determine a second time of flight corresponding to the phase shift.