Ultrasonic Flow Sensor on Flexible Conduit for High-Pressure Biopharma
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Solution Overview
Problem
Conventional flow sensors are not suitable for high-pressure applications in pharmaceutical and biologic manufacturing processes, as they can burst or fail due to expansion forces and are not compatible with reinforced tubing, which also limits the ability to create sharp bends in conduit systems, leading to inefficient layouts and product loss.
Innovation Solution
A fluid monitoring assembly featuring a flexible conduit with a flow sensor mounted externally and housed in a two-part enclosure, using ultrasonic transducer/receiver pairs to measure flow rate non-invasively, capable of withstanding high pressures and integrated into a two-part housing that prevents bursting, allowing for accurate flow measurement without interfering with reinforced tubing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional flow sensors are used in high-pressure applications, then flow rate measurement is achieved, but the conduit or sensor unit bursts or fails due to expansion forces
Solution Approach 1:
An unreinforced conduit segment is introduced as an intermediary component between reinforced conduit sections. This intermediate segment is flexible enough to accommodate the flow sensor and withstand high pressures without bursting, while allowing the overall system to maintain structural integrity through the reinforced sections.
Solution Approach 2:
The flow sensor is nested within or mounted on the exterior of the unreinforced conduit segment, creating a hierarchical structure where the sensor is protected by the conduit while the conduit itself is protected by the flexible housing that encloses both.
2Stress or pressure
If reinforced conduit or tubing is used for high pressure applications, then pressure resistance is improved, but the conduit cannot be configured with sharp bends or curves requiring long sections
Solution Approach 1:
The conduit system is divided into segmented sections: reinforced conduit segments for high-pressure straight runs, and flexible unreinforced conduit segments for bending and routing. This segmentation allows each section to perform its optimal function while working together as an integrated system.
3Ease of operation
If unreinforced tubing is used, then flexibility for bending is improved, but the tubing may fail or burst under higher pressures
Solution Approach 1:
The conduit system employs local quality by using unreinforced tubing specifically at the location where flexibility is needed (around the flow sensor and in bending sections), while reinforced tubing is used in sections requiring high pressure resistance. Each section's properties are optimized for its specific functional requirement.
4Reliability
If reinforced conduit is used, then pressure resistance is improved, but flow measurement signals are interfered with by braiding or reinforcement
Solution Approach 1:
The reinforcement (braiding or strengthening layer) is extracted or removed from the conduit segment that requires flow measurement. This creates an unreinforced section where the flow sensor can operate without interference from metallic braiding or reinforcement, while the overall system maintains pressure resistance through other reinforced sections.
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 reliable and accurate flow rate measurement in high-pressure environments, preventing conduit failure and maintaining operational integrity, while allowing for flexible conduit configurations without the need for long sections, thus reducing product loss and system complexity.
Implementation Method 1
The flow sensor (12) is able to detect the flow rate of fluid passing through the flexible conduit (14) in a non-invasive manner
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A fluid monitoring assembly for measuring the flow rate of a fluid includes a flexible conduit comprising a wall that defines a lumen through which the fluid passes. In one embodiment, a flow sensor is removably secured around the outside of the flexible conduit, the flow sensor having one or more transducer/receiver pairs. The assembly includes a housing having first and second portions connected to one another at a hinge, the first and second housing portions each defining respective recessed interior portions that define a cavity that is configured to encapsulate and retain the flow sensor and flexible tubing contained therein. In an alternative embodiment, the flow sensor is directly embedded or integrated into the housing.