Flow Sensors

Flow - mass flow rate - volume flow rate - velocity - stream line parabolic velocity profile - turbulent vortices

Types of flow

Methods of measurement

- direct: positive displacement (batch sensors, metering pumps) - indirect: measurement of velocity or kinetic energy

Flow Sensors
Classification: a) volume flow rate b) mass flow rate c) velocity
V Qv = , t Qm = m t V Qm = t

Qv = v S ,

Qm = v S

Flow Sensors
Volume flow rate sensors: - rotameters (float) - batch/oval gear - velocity: - turbine, paddle wheel - vortices - electromagnetic - ultrasonic - with moving marks - obstruction devices Mass flow rate sensors: - thermal - Coriolis force

Flowmeters with float

Rotameter Gravity
Float acts as force balance indicator

Float (buoy)
Flow

Glass tube

viscosity insensitive =>sharp edges on float

Velocity based flowmeters

Turbine flowmeter

linearity 0 1% threshold 2 3% range

Velocity based flowmeters

Turbine flowmeters
frequency of pulses f proportional to velocity:

f = KQv

Kconstant of flowmeter QV volume flow

Lower limit of accuracy: 3 5% linearity: 0,1%

Criterion of nonlinearity:

r D2 Qv = f 3 r D

Ddiameter of turbine pipe viskoziy of fluid

lin.dependence of ang, velocity of rotor r on velocity of flow v drop of pulse amplitude for low v (not in Hall sensor)

Velocity based flowmeters

Paddle-wheel sensor + cheaper - less precise

Velocity based flowmeters

Velocity based flowmeters

Vortex Shedding flowmeter
Karman vortices

Bluff body

Sr f = v a

Detection of vortices: thermoanemometers ultrasonic detectors pressure detectors

ffrequency of vortices A characteristic dimension of obstacle Sr Strouhal number (char. for certain shape of obstacles)

Accuracy ~ 1%

Marking flowmeters

Mark

- conductive (injection of electrolyte to liquid) - optical (injection of colouring agent) - thermal - ionisation (admixture of radioisotope)

Principle: measurement of time interval of mark transit between two points in direction of liquid flow

Correlation based velocity measurement

Ultrasonic flowmeters

Pulse ultrasonic flowmeter is based on addition of vectors velocity of liquid flow and velocity of ultrasound propagation. The measured value is time of propagation of pulse from transmmiter to receiver.

L t 2 t1 v= 2 cos t1 t 2
t1time interval of propagation from (V2,P2) to (V1,P1 ) t2time interval of propagation from (V1,P1)tok (V2,P2 )

Ultrasonic flowmeters

Doppler type of ultrasonic flowmeter (non wetted type)

Works in continuos wave mode CW (not in pulse mode) Similarly to radar trafic speed measurement measure Doppler shift of frequency Principle: reflection of ultrasonic wave from bubbles or dispersed particles

Induction (electro-magnetic) flowmeters

analogy to Hall effect

Usual accuracy: through flow type 0,2%, immersion type 2%

Induction (magnetic) flowmeters

Construction of flowmeter with saddlebacked coils

Induction (magnetic) flowmeters

Immersion type

Sensors of flow with obstruction devices

Pressure drop (pressure difference) on obstructions devices (orifice,flow nozzle, Venturi tube)

Qv =

d 2
4

p1 p 2

1 pd = v 2 2

Qvvolume, expansion coefficient diameter

Accuracy 2% (0,5%)

Sensors with conversion of flow to deformation (drag-force flowmeters)

On the target immersed in the flowing medium acts drag - force Fd

Cd S v 2 Fd = 2
Cdconstant of the target Scrossection area density of liquid vvelocity

Accuracy several %

good dynamic response - resonant frequency up to 200 Hz

Oval gear flowmeters, metering pumps

Badgermeter co.

Used for balance (audit) flowmetering 1 dm3/h 103 dm3/h

Thermal mass flowrate sensors (flowmeters)

Exchange of heat between source and surroundings (fluid) - measurement of cooling of heat source (thermoanemometer) - measurement of warming up of fluid

Thermoanemometer 2 ways of operation: -constant temperature of wire (feedback- excellent dynamic response) -constant current

Thermal sensor of mass flowrate

Mode of operation of thermoanemometers -const. current (change of flow velocity => change of temperature => => change of resistance => bridge not balanced) -const.temperature of wire (bridge balanced for maximum flow, drop of v => less cooling effect => => drop of heating current)

Output current

i 2 = a + b Qm a <= transfer of heat to surroundings b <= phys. properties of fluid

Thermal sensor of mass flowrate

Differential thermoanemometer

Response to the step change of velocity

1constant current 2constant temperature

Thermal sensor of mass flowrate

Differential thermoanemometer

At v = 0 ...R1=R2 at v > 0 cooling R1 and warming up R2 (<= heat from RH)

Suitable for MEMS
increased sensitivity, elimination of temperature influence, suitable for small flowrates (10-4 mm3.s-1)

Thermal sensor of mass flowrate

Differential sensor
Thomas principle

Bridge evaluates the temperature difference 1-2 measured by S1 and S2 ( 2 1 ) Qm = A Pq

Aconstant Cpspecific heat capacity of fluid PQthermal flux from heating windings T

sensor of small mass flowrate (shunt)

Coriolis flowmeter

Coriolis force Fc is perpendicular to the axis of rotation and direction of movement

FC depends on

- angular velocity f (ot/s) - mass of the body m (kg) - velocity of body w (m/s)

FC = 2 m (w ) = 4 m w f

Coriolis flowmeter

l FC = 2vm = 2 m = 2Qml t
Tube filled by liquid flowing with velocity w: when rotating around axis z Coriolis force Fc acts on liquid Fc is perpendicular to the axis of rotation and direction of flow and has a tendency to bow the tube

Coriolis flowmeter
One of rarely occuring principles of direct mass flowrate measurement

Coriolis flowmeter = type with U tube

Magnetic force Fm causes vibrations of tube around the axis . Fc produces twisting of tube.

!sediments in U tube -> linear tube

M = 2dFC = 4dbQm

t Qm

Level sensors
Analogue output Binary output (level switch) Liquids only Slurry Powders, granules

Level sensors

Level sensors
Many principles, but only a few really massively used 90% of applications just 4 types:
Pressure / differential pressure Float Ultrasound Radar

Pressure

Open vessel

Closed vessel => pressurized vapours above level

Pressure bubbler

Pressure sensor not in contact with liquid

Float + reed switch (~analog)

Float + reed switch (binary)

Float + flag

Float + weight (Archimedes)

Float + Magnetostrictive

Balluff

Ultrasonic (time of flight)

Beam width can be critical in narrow vessels

Ultrasonic level switch

Transmission from source to detector changes when water fills the space

Radar
Measurement: TDR (time domain radar) FMCW (frequency-modulated, continuous wave) Arrangement: Antenna (dish or conical) Waveguide (+ better signal)

Radar TDR

Radar FMCW

Radar antennae - parabolic

Tanker (crude oil) radar sensors - SAAB

Radar antennae - cone

Tanker (crude oil) radar sensors - SAAB

Radar guided wave

Special sensors less frequently used

Tuning fork Yo-yo Paddle wheel Optical Conductive Dip stick

Tuning fork

Yo-yo

Paddle wheel

Motor must survive static (jammed) operation

Optical switch

Braking the condition of total reflection

Conductive

Dip stick
Normal dip stick in every car (oil level checking) Here: a high-tech dip stick