Test stand data table-based fluid flow device with remote calibration system and method
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Solution Overview
Problem
Current fluid flow measurement devices are expensive and have limited turndown ratios, making them ineffective for accurately measuring low fluid flows, particularly in HVAC systems, leading to energy inefficiency and discomfort due to the inability to control air flow accurately.
Innovation Solution
A fluid flow measurement and control system utilizing a multi-stage damper with a variable orifice plate and actuator assembly, which includes nested elements and a controller to determine flow rates based on pressure differentials and flow coefficients, enabling precise control over a wide range of fluid flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional fluid flow measurement devices are used, then measurement capability is provided, but cost is high and turndown ratio is limited
Solution Approach 1:
The fluid flow control device is divided into multiple independent control elements (first control element and second control element) that can be adjusted separately. Each control element has its own actuator and control mechanism, allowing independent optimization of different flow ranges. This segmentation enables the system to achieve high measurement precision across a wide turndown ratio without requiring a single complex expensive device.
2Adaptability or versatility
If conventional fluid flow measurement devices are used, then measurement capability is provided, but turndown ratio is limited to less than 10:1
Solution Approach 1:
The device employs dynamic control elements that can change their configuration continuously. The control elements include adjustable orifices and variable geometry components that can be modified in real-time to adapt to different flow conditions. This dynamic capability enables the system to maintain measurement precision across a wide turndown ratio from high to low fluid flows.
Solution Approach 2:
The device incorporates nested control structures where smaller control elements are positioned within or alongside larger ones. The first and second control elements are arranged in a nested configuration, allowing the smaller precision control element to handle low flow measurements while the larger element manages high flow conditions, achieving a turndown ratio greater than 10:1 with maintained precision.
3Measurement precision
If HVAC systems run at minimum measurable flow to ensure accuracy, then measurement accuracy is maintained, but energy consumption increases
Solution Approach 1:
The HVAC system uses dynamically adjustable control elements that can be optimized for different operating conditions. The control elements can be adjusted to maintain accurate flow measurement and control even at reduced flow rates, allowing the system to operate at lower speeds and consume less energy while maintaining measurement precision through the advanced control mechanism.
4Adaptability or versatility
If multiple control elements are used to achieve wide turndown ratio, then flow control range is improved, but device complexity increases
Solution Approach 1:
The device merges multiple control elements into a single integrated assembly. The first and second control elements are combined in a compact configuration with shared mounting structures and control mechanisms. This merging approach achieves a wide flow control range through multiple elements while minimizing the increase in overall device complexity through efficient spatial arrangement and shared components.
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 a high turndown ratio, allowing for accurate measurement and control of fluid flows, reducing energy consumption and enhancing comfort by enabling precise control of air flow in HVAC systems, while also simplifying system designs and reducing manufacturing costs.
Implementation Method 1
a first sensor disposed upstream of, and a second sensor downstream of, the orifice plate... determine a pressure differential based on a first pressure obtained between the first and second sensors
Data Source
AI summary
A method for calibrating a product fluid flow valve disposed along a flow path in a site duct, and including damper blades, an actuator coupled thereto, a differential pressure sensor, and a blade controller adapted to define adjustable product flow apertures, comprising the steps: with a calibration fluid flow valve in a calibration duct remote from the product fluid flow valve, and characterized by a geometric shape and operational parameters corresponding to those of the product fluid flow valve, and with a calibration controller, establishing a plurality of calibration conditions including pressure drop across the calibration blades and area of the calibration apertures, determining a calibration flow rate (CFM) function, transferring the CFM function to the product blade controller and adjusting the adjustable product flow apertures so that a parameter set point is attained. In a form, fluid flowing through the product flow apertures forms a vena contracta.