Spherical Flow Sensor with Internal Strain Gauges
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Solution Overview
Problem
Existing fluid flow monitoring technologies face challenges in accurately and reliably measuring parameters of rheologically complex fluids, such as particulate and multiphase media, due to issues like particle deposition, contamination, and mechanical failure, especially in chemically aggressive and high-viscosity environments.
Innovation Solution
A system comprising a sensor package with a spherical body member and strain gauges that deform based on fluid drag, allowing for continuous in situ monitoring of fluid flow parameters like flow rate, viscosity, and particle mass, while minimizing contact with the fluid to prevent contamination and mechanical issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If intrusive sensors with moving parts are used to measure fluid flow parameters, then measurement capability is improved, but reliability deteriorates due to particle deposition and mechanical failure
Solution Approach 1:
The invention extracts the measurement function from the fluid-contacting surface by using strain gauges mounted on the internal surface of the cavity, isolated from the particulate fluid flow. This allows the external surface to be smooth and particle-free while still capturing fluid drag forces through wall deformation, resolving the contradiction between measurement capability and reliability.
Solution Approach 2:
The cavity wall acts as an intermediary element that transmits fluid drag forces from the external surface to the internal strain gauges. This mediator allows indirect measurement of fluid parameters without direct contact between sensing elements and the aggressive fluid environment, improving both reliability and measurement precision.
2Measurement precision
If sensors are placed in direct contact with particulate fluid flow, then measurement sensitivity is improved, but device complexity increases due to cleaning and maintenance requirements
Solution Approach 1:
The sensing function is extracted from the external surface and relocated to the internal surface of the cavity, eliminating the need for external surface cleaning. The strain gauges measure wall deformation caused by fluid drag without being exposed to particles, thus reducing device complexity while maintaining measurement sensitivity.
Solution Approach 2:
Instead of placing strain gauges on the external surface exposed to fluid (conventional approach), the invention inverts the arrangement by mounting strain gauges on the internal surface isolated from fluid. This inversion eliminates cleaning requirements while preserving the ability to detect fluid drag forces through wall deformation.
3Reliability
If optical sensors are used for non-intrusive flow measurement, then reliability is improved, but measurement precision deteriorates in opaque and particulate fluids
Solution Approach 1:
The invention replaces optical sensing with mechanical sensing (strain gauges) that measure physical deformation of the cavity wall. This substitution enables reliable operation in opaque and particulate fluids where optical methods fail, while maintaining measurement precision through direct mechanical coupling to fluid drag forces.
Solution Approach 2:
The cavity wall serves as a mechanical intermediary that transmits fluid drag forces to the strain gauges. This mechanical mediation allows accurate measurement of fluid parameters in opaque and particulate flows without requiring optical transparency, resolving the contradiction between reliability and measurement precision.
4Adaptability or versatility
If acoustic waves are used for flow measurement, then adaptability to complex fluids is improved, but measurement precision deteriorates due to wave scattering by particles
Solution Approach 1:
The invention replaces acoustic wave-based measurement with direct mechanical strain measurement. Strain gauges on the cavity wall directly measure deformation caused by fluid drag, avoiding the scattering and reflection issues that plague acoustic methods in particulate and complex fluids, thus improving measurement precision while maintaining adaptability.
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 system provides robust and reliable monitoring of fluid flow parameters with reduced maintenance needs and increased component lifespan, suitable for complex fluid flows in various industrial applications.
Implementation Method 1
The first external surface segment and the first internal surface segment are each respectively configured to deform based, at least in part, on the drag of the fluid flow
Implementation Method 2
The first external surface segment and the first internal surface segment are each respectively configured to deform based, at least in part, on the drag of the fluid flow
Implementation Method 3
The first strain gauge is positioned in the cavity of the body member and configured to measure the deformation of the first internal surface segment
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Flow sensors, systems, and methods for continuous in situ monitoring of a Theologically complex fluid flow within a vessel, such as particulate and multiphase media for ascertaining certain fluid flow parameters, such as flow rate, dynamic viscosity, fluid density, fluid temperature, particle density and particle mass, from flow sensor measurements. The system involves a fluid flow sensor having a body member with internalized strain gauges configured to measure the deformation of certain segments of the body member. Based, at least in part, on these deformation measurements, the system is used to compute the fluid flow parameters.