Sealed Gear Flow Meter with Optical Sensor
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Solution Overview
Problem
Traditional gear flow meters with timing gear systems require apertures for external gear coupling, which can compromise sealing and introduce environmental and fluid compatibility issues, while non-contact sensors offer a solution but may face challenges in accurately measuring fluid flow characteristics like volume, direction, and rate across varying applications.
Innovation Solution
A gear flow meter design incorporating a housing with a sealed chamber and a non-contact optical sensor outside the chamber, utilizing a separation member that is transparent to the sensor wavelength range and includes an optical filter to limit external radiation, allowing precise detection of gear movement without compromising the seal or fluid compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external timing gear systems are used to measure gear rotation, then measurement capability is provided, but sealing is compromised and environmental/fluid compatibility issues are introduced
Solution Approach 1:
The flow meter is divided into two separate sections: a fluid handling section with the chamber and gears, and a measurement section with the optical sensor. The separation member creates a barrier between these sections, allowing each to be optimized independently - the chamber can be perfectly sealed for fluid compatibility while the sensor section remains accessible for measurement.
Solution Approach 2:
An optical intermediary system is introduced consisting of the separation member with transparent window and the optical sensor. This intermediary allows measurement information to pass through the seal boundary without compromising the physical seal, enabling non-contact measurement while maintaining sealing integrity.
2Reliability
If a sealed chamber is used to maintain fluid compatibility and prevent contamination, then sealing and reliability are improved, but non-contact measurement of gear movement becomes challenging
Solution Approach 1:
The separation member acts as an optical intermediary, containing a window or transparent section that allows optical signals to pass through while maintaining the physical seal. This enables the optical sensor to detect gear movement through the sealed barrier without compromising fluid containment.
Solution Approach 2:
The mechanical coupling system (timing gears and shafts) that physically connected the measurement mechanism to the fluid handling section is replaced with an optical detection system. This substitution eliminates the need for mechanical penetrations through the seal, allowing non-contact measurement while maintaining sealing integrity.
3Reliability
If optical sensors are positioned outside the chamber to avoid sealing issues, then sealing is maintained, but external radiation may interfere with sensor detection
Solution Approach 1:
The separation member is designed with different optical properties in different locations: it is opaque in most areas to block external radiation, but contains a specific transparent window or section that allows sensor wavelengths to pass through. This localized transparency enables precise measurement while the rest of the structure maintains radiation shielding.
Solution Approach 2:
The separation member is engineered to be substantially transparent to specific sensor wavelength ranges while blocking other wavelengths. By selecting appropriate sensor wavelengths that match the transparency characteristics of the separation member material, the system achieves both sealing integrity and measurement precision.
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
Enables accurate measurement of fluid flow characteristics such as volume, rate, and direction with improved sealing and adaptability to different fluids and environments, enhancing the reliability and versatility of fluid flow measurement systems.
Implementation Method 1
The non-contact sensor is an optical sensor comprising an emitter configured to emit radiation in a sensor wavelength range and a detector configured to detect radiation in the sensor wavelength range
Implementation Method 2
The optical filter comprises a material substantially opaque to the sensor wavelength range, the optical filter positioned to limit radiation within the sensor wavelength range from entering the chamber from outside the flow meter
Implementation Method 3
At least a portion of the separation member is substantially transparent to the sensor wavelength range
Data Source
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AI summary
Fluid flow meters and methods for measuring different aspects of fluid flow with a non- contact sensor are provided. In some cases a fluid flow gear meter is provided with a fluid chamber that is sealed with a cover portion carrying the non-contact sensor. An optional separation member may be located between the cover portion and the chamber to seal the chamber. In some cases the cover portion and/or separation member are configured to transmit visible light to allow viewing of the fluid chamber, through material selection and/or the presence of viewing cavities within the material. The flow meter is optionally configured to prevent or reduce the transmission of ambient environmental radiation into the flow meter to lessen the likelihood that it may adversely affect an optical non-contact sensor used to detect movement of gears within the chamber.