Thermal Flow Sensor Tilt Angle Correction
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Solution Overview
Problem
Thermal flow sensors installed at varying angles in a flow path suffer from inaccurate flow rate measurements due to convection heat effects, which affect the output values from thermopiles, leading to inconsistent and inaccurate flow rate calculations.
Innovation Solution
A flow rate measurement device comprising a heating unit, temperature sensing units, an angle calculation unit, and a storage unit that corrects flow rates based on tilt angles, using pre-stored correction values to account for convection heat, ensuring accurate measurements regardless of sensor orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermal flow sensors are installed at varying angles in a flow path, then the device can be installed in different orientations, but the measurement accuracy deteriorates due to convection heat effects affecting thermopile output values
Solution Approach 1:
The system performs preliminary action by measuring the tilt angle of the thermal flow sensor before flow rate measurement, and pre-stores correction values corresponding to different tilt angles. This allows the system to compensate for convection effects in advance, ensuring accurate measurements regardless of installation angle.
Solution Approach 2:
The system changes the parameter being measured by detecting the tilt angle of the sensor and selecting appropriate correction values from stored data. By varying the correction parameter based on tilt angle, the system maintains measurement accuracy across different installation orientations.
2Ease of manufacture
If thermal flow sensors are installed without angle correction, then the installation process is simplified, but convection heat causes inaccurate flow rate measurements
Solution Approach 1:
The thermal flow sensor system performs self-correction by automatically detecting its own tilt angle and applying appropriate correction values from stored data. This self-service mechanism eliminates the need for manual angle adjustment or complex installation procedures while maintaining high measurement accuracy.
Solution Approach 2:
The system automatically adjusts the measurement parameter by applying tilt-angle-specific correction values, transforming the raw thermopile output into accurate flow rate measurements without requiring manual intervention for angle compensation.
3Measurement precision
If tilt angle detection and correction mechanisms are added to thermal flow sensors, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The system introduces a tilt angle detection unit as an intermediary component that measures sensor orientation and uses a correction value storage unit as a mediator to provide pre-calculated correction factors. This intermediary approach adds minimal complexity while significantly improving measurement accuracy.
Solution Approach 2:
The correction values for different tilt angles are pre-calculated and stored in the correction value storage unit, performing the complex compensation calculation in advance. This preliminary action eliminates the need for real-time complex computations, keeping the device complexity low while maintaining high accuracy.
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 device provides highly accurate flow rate measurements by accounting for convection heat effects and sensor tilt, improving measurement precision and stability across different installation angles.
Implementation Method 1
a heating unit for heating a fluid
Implementation Method 2
temperature sensing units that are provided flanking the heating unit in the direction of fluid flow, and that sense the temperature of the heated fluid
Implementation Method 3
When a fluid is heated by a heater, convection may occur in the vicinity of the heater, whereby heat is carried upward with respect to the horizontal plane
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The flow rate measurement device according to one aspect of the present invention comprises a heating unit for heating a fluid; temperature sensing units that are provided flanking the heating unit in the direction of fluid flow, and that sense the temperature of the heated fluid; a flow rate calculation unit that calculates the flow rate of the fluid on the basis of a sensing signals outputted from the temperature sensing units; angle calculation unit for calculating the tilt angle of the temperature sensing units with respect to a specific reference plane; a storage unit that stores the relation between the flow rate, the tilt angle, and a flow rate correction value; and a flow rate correction unit that corrects the flow rate by using the flow rate correction value stored in the storage unit.