Ultrasonic Flow Meter Conditioning for High-Pressure Accuracy
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Solution Overview
Problem
Existing ultrasonic flow meters face challenges in maintaining accuracy and reliability under extreme fluid environmental conditions, such as high pressures and temperatures, and are affected by flow instabilities and fluid density variations, particularly in applications like aircraft gas turbine engines, which require high turndown ratios and dynamic accuracy.
Innovation Solution
The system includes a fluid flow conditioning apparatus with linear fluid conduits and ultrasonic sensor modules that condition fluid flow through convergent and divergent geometries, using ultrasonic signals to determine mass and volume flow rates, while protecting transducers from direct fluid exposure and pressure effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ultrasonic flow meters are used in extreme fluid environmental conditions (high pressure and temperature), then the measurement capability is maintained, but the reliability and accuracy deteriorate due to flow instabilities and fluid density variations
Solution Approach 1:
The flow conditioning apparatus segments the flow path into distinct zones: a conditioning zone with convergent and divergent geometries that stabilizes flow, and a measurement zone where ultrasonic transducers operate. This segmentation isolates the transducers from turbulent flow conditions while maintaining measurement capability, resolving the contradiction between reliability in extreme conditions and measurement precision.
Solution Approach 2:
The flow conditioning apparatus acts as an intermediary between the extreme fluid environment and the ultrasonic transducers. It conditions the flow by reducing turbulence and stabilizing velocity profiles before the fluid reaches the measurement zone, thereby protecting the transducers from flow instabilities while enabling accurate measurements under high pressure and temperature conditions.
2Measurement precision
If flow conditioning is added to stabilize fluid flow, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The flow conditioning apparatus merges multiple functions into a single integrated structure: flow stabilization, velocity profile conditioning, and transducer protection are combined in one component assembly. This merging reduces overall system complexity compared to having separate components for each function, while still achieving improved measurement accuracy through effective flow conditioning.
3Adaptability or versatility
If high turndown ratios are required for fuel systems, then adaptability improves, but measurement precision deteriorates due to flow instabilities at low flow rates
Solution Approach 1:
The flow conditioning apparatus performs preliminary action by stabilizing the flow and establishing a uniform velocity profile before the fluid enters the measurement zone. This pre-conditioning ensures that even at low flow rates within the high turndown ratio range, the flow remains stable and laminar, enabling accurate ultrasonic measurements across the entire operating range from high to low flow rates.
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 design enhances environmental survivability, maintains accuracy across wide temperature and pressure ranges, reduces sensitivity to flow dynamics, and provides integral density sensing, enabling high turndown ratios and update rates of 100Hz or greater.
Implementation Method 1
two ultrasonic sensor modules configured to transmit an ultrasonic signal through the first conditioner outlet, the fluid conduit, and the second conditioner inlet along the linear fluid flow path
Implementation Method 2
determine at least one of a mass flow rate and a volume flow rate of the fluid flow based on the received ultrasonic signal
Implementation Method 3
a tubularly convergent portion having a predefined geometry proximal the conduit outlet and configured to partly restrict fluid flow along the linear fluid flow path
Implementation Method 4
a tubularly divergent portion having a predefined geometry proximal the conduit outlet and configured to partly expand fluid flow along the linear fluid flow path
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The subject matter of this specification can be embodied in, among other things, a fluid flow conditioning apparatus that includes a linear fluid conduit configured to define a linear fluid flow path, a fluid inlet defining an inlet fluid flow path that is non-parallel to the linear fluid flow path, a first fluid flow conditioner having a first conditioner configured to receive fluid flow along the inlet fluid flow path, condition fluid flow, and redirect conditioned fluid flow away from the inlet fluid flow path along the linear fluid flow path along the major axis, a second fluid flow conditioner configured to receive fluid flow from the linear fluid flow path along the major axis, redirect fluid flow away from the linear fluid flow path along an outlet fluid flow path that is non-parallel to the linear fluid flow path, and condition fluid flow, and a fluid outlet.