Ultrasonic Process Transmitter for Non-Intrusive Multivariable Sensing
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Solution Overview
Problem
Existing industrial process variable measurement techniques often require intrusive methods that disrupt the process fluid, which is undesirable in certain applications, and there is a need to measure multiple process variables non-intrusively.
Innovation Solution
An ultrasonic multivariable process transmitter that uses an ultrasonic transmitter to transmit and receive pulses through a pipe wall, correlating the reflected vibrations with process variables such as wall thickness, temperature, and pressure, without direct contact with the process fluid, using EMAT sensors, and processing circuitry to analyze and provide outputs indicative of these variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If intrusive measurement methods are used to measure process variables, then measurement accuracy is improved, but process disruption and safety risks increase
Solution Approach 1:
The patent uses ultrasonic waves as an intermediary to transmit measurement information through the pipe wall without direct contact with the process fluid. The ultrasonic transmitter sends pulses through the wall, and the receiver detects reflected or transmitted pulses, allowing measurement of process variables (temperature, pressure, flow rate) while maintaining physical separation from the hazardous fluid.
Solution Approach 2:
The patent replaces intrusive mechanical sensors with non-contact ultrasonic sensing. Instead of inserting physical measurement devices into the process fluid, the system uses ultrasonic vibrations to probe the pipe wall and infer process variables from changes in the ultrasonic signal characteristics, eliminating the need for direct mechanical contact with the process fluid.
2Adaptability or versatility
If multiple process variables are measured using separate intrusive sensors, then measurement comprehensiveness is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent implements a single ultrasonic transmitter-receiver system that can measure multiple process variables (temperature, pressure, flow rate, wall thickness) simultaneously by analyzing different characteristics of the ultrasonic signal. The same hardware platform performs multiple measurement functions, eliminating the need for separate sensors for each variable.
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated ultrasonic measurement system. The transmitter and receiver work together to provide comprehensive process monitoring through one device, merging what would traditionally require multiple separate intrusive sensors into a unified non-intrusive platform.
3Difficulty of detecting and measuring
If intrusive sensors are installed to access process fluid for measurement, then measurement capability is improved, but process barrier interruption and safety risks increase
Solution Approach 1:
The ultrasonic wall acts as an intermediary medium that allows measurement information to pass through without breaking the process barrier. The pipe wall itself becomes the transmission path for ultrasonic waves, enabling measurement while maintaining the integrity of the containment barrier and preventing direct contact between the sensing system and the process fluid.
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 non-intrusive measurement of multiple process variables, including wall thickness, temperature, and pressure, providing accurate and remote monitoring of industrial processes with reduced risk and cost.
Implementation Method 1
an ultrasonic transmitter to transmit a pulse of input ultrasonic vibrations into a proximal surface of a wall
Implementation Method 2
The pulse of input ultrasonic vibrations propagate through the wall and reflect from a distal surface of the wall to form a reflected pulse of output ultrasonic vibrations
Implementation Method 3
Processing circuitry correlates a sequence of sample values of the received reflected pulse of output ultrasonic vibrations with changes in the surface of the wall
Data Source
AI summary
An ultrasonic multivariable process transmitter includes an ultrasonic transmitter configured to transmit a pulse of input ultrasonic vibrations into a proximal surface of a wall. The pulse propagates through the wall and reflects from a distal surface to form a reflected pulse of output ultrasonic vibrations. An ultrasonic receiver receives pulses of ultrasonic vibrations at the proximal surface. Processing circuitry correlates the received reflected pulse of output ultrasonic vibrations with changes in the surface of the wall. The received pulses are further a function of a process variable of a process related to a process fluid in contact with a surface of the wall. An output indicative of the process variable of the process is provided.