U.S. patent application number 10/980092 was filed with the patent office on 2005-04-28 for single-body dual-chip orthogonal sensing transit-time flow device.
This patent application is currently assigned to PTI TECHNOLOGIES, INC.. Invention is credited to Kantor, Francis H., Moscaritolo, Daniel K., Sandoval Diaz, Fermin A..
Application Number | 20050087025 10/980092 |
Document ID | / |
Family ID | 32507372 |
Filed Date | 2005-04-28 |
United States Patent
Application |
20050087025 |
Kind Code |
A1 |
Moscaritolo, Daniel K. ; et
al. |
April 28, 2005 |
Single-body dual-chip orthogonal sensing transit-time flow
device
Abstract
An ultrasonic sensor, including methods of using and installing
same, the sensor having a pair of ultrasound transducers adapted to
be inserted in, and being able to perform at, a single site of
introduction into a duct. The ultrasonic sensor measures a forward
ultrasonic path transit time and a second reverse ultrasonic path
transit time of ultrasound signals propagating in a fluid, the
arrangement being such that a comparison of the signal associated
with ultrasound travel in one direction with the signal associated
with ultrasound travel in the opposite direction enables the flow
rate of the fluid in the duct to be determined. The sensor may
utilize a reflecting surface on the duct and a reflective surface
of an ultrasonic sensor end cap to provide forward and reverse
ultrasonic W-shaped paths. In addition, the ultrasonic sensor may
be used to measure the temperature, viscosity, and cavitation
effects of a fluid.
Inventors: |
Moscaritolo, Daniel K.;
(Thousand Oaks, CA) ; Kantor, Francis H.; (Newbury
Park, CA) ; Sandoval Diaz, Fermin A.; (Camarillo,
CA) |
Correspondence
Address: |
Keyvan Davoudian
PILLSBURY WINTROP LLP
Suite 2800
725 South Figueroa Street
Los Angeles
CA
90017-5406
US
|
Assignee: |
PTI TECHNOLOGIES, INC.
|
Family ID: |
32507372 |
Appl. No.: |
10/980092 |
Filed: |
November 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10980092 |
Nov 3, 2004 |
|
|
|
10334082 |
Dec 30, 2002 |
|
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Current U.S.
Class: |
73/861.27 ;
73/270 |
Current CPC
Class: |
G01F 1/667 20130101;
G01F 1/662 20130101 |
Class at
Publication: |
073/861.27 ;
073/270 |
International
Class: |
G01F 003/20 |
Claims
What is claimed is:
1. A method of installing an ultrasonic sensor into an existing
duct assembly, comprising: removing an existing fluid sensor from
an existing duct assembly; mounting a retrofit assembly, including
a boot structure with a mounting flange, to the duct assembly, the
duct assembly including a duct for providing a flow path for a
fluid; machining a reflecting surface; removing contamination from
the boot structure; and installing an ultrasonic sensor.
2. The method of claim 1, further including collecting the
contamination in the boot structure during the machining step.
3. The method of claim 1, wherein the reflecting surface is
machined into an interior surface of the duct.
4. The method of claim 1, wherein the ultrasonic sensor includes a
first transducer to transmit a signal, a second transducer to
receive the signal, and an end cap, said end cap enclosing and
isolating said first and second transducers from said fluid and
having a reflective surface in contact with the fluid.
5. The method of claim 4, wherein the first and second transducers
are oriented at an angle with respect to an axis orthogonal to a
central axis of the duct.
6. The method of claim 4, wherein the reflecting surface is
machined into a wall of the duct located opposite said reflective
surface.
7. The method of claim 6, wherein the ultrasonic sensor is
installed such that the signal transmitted by the first transducer
approximately traverses a W-shaped path that extends from the first
transducer to the reflecting surface, then to the reflective
surface, then to the reflecting surface, and finally to the second
transducer.
8. The method of claim 1, wherein the machining step comprises
machining a first angled reflecting surface and a second angled
reflecting surface into a wall of the duct.
9. The method of claim 8, wherein said first and second angled
reflecting surfaces are substantially flat.
10. The method of claim 1, wherein, in the last step, the
ultrasonic sensor is installed so as to be flush with the interior
wall of the duct.
11. The method of claim 1, wherein said contamination is removed
using a vacuum source.
12. A method of retrofitting an existing duct assembly with an
ultrasonic sensor, the method comprising: removing an existing
fluid sensor from an existing duct assembly so as to expose an
existing hole pattern in the duct assembly, said duct assembly
including a duct for providing a flow path for a fluid; mounting a
retrofit assembly, including machining equipment and a boot
structure, to the duct assembly; inserting the machining equipment
through the hole pattern to machine a reflecting surface in the
duct while containing metal shards in the boot structure;
withdrawing the machining equipment through the hole pattern;
removing contamination from the boot structure; and installing an
ultrasonic sensor in place of the removed fluid sensor.
13. The method of claim 12, wherein the reflecting surface is
machined into an interior surface of the duct.
14. The method of claim 12, wherein the ultrasonic sensor is a flow
sensor and includes a first transducer to transmit a signal, a
second transducer- to receive the signal, and an end cap, said end
cap enclosing and isolating said first and second transducers from
said fluid and having a reflective surface in contact with the
fluid.
15. The method of claim 14, wherein the reflecting surface is
machined into a wall of the duct located opposite said reflective
surface.
16. The method of claim 15, wherein the ultrasonic sensor is
installed such that the signal transmitted by the first transducer
approximately traverses a W-shaped path that extends from the first
transducer to the reflecting surface, then to the reflective
surface, then to the reflecting surface, and finally to the second
transducer.
17. The method of claim 14, wherein the first and second
transducers are oriented at an angle with respect to an axis
orthogonal to a central axis of the duct.
18. The method of claim 12, wherein the machining step comprises
machining a first angled reflecting surface and a second angled
reflecting surface into a wall of the duct.
19. The method of claim 18, wherein said first and second angled
reflecting surfaces are substantially flat.
20. The method of claim 12, wherein, in the last step, the
ultrasonic sensor is installed so as to be flush with the interior
wall of the duct.
21. The method of claim 12, wherein said contamination comprises
the metal shards and is removed using a vacuum source.
Description
RELATED APPLICATION DATA
[0001] This is a divisional of application Ser. No. 10/334,082,
filed Dec. 30, 2002, now U.S. Pat. No. ______.
BACKGROUND
[0002] 1. Technical Field
[0003] An embodiment of the present invention generally relates to
an ultrasonic flow sensor. More particularly, an embodiment of the
present invention relates to a transit-time ultrasonic flow sensor
to measure a flow rate, temperature, and cavitation effects.
[0004] 2. Discussion of the Related Art
[0005] The use of insertion monitoring devices to measure fluid
flow rate are restricted by cost and practical problems. For
example, in one known insertion metering device, a probe is
inserted into a duct through a hole or valve opening in the duct
wall. The probe comprises a rod which carries a turbine or
electromagnetic sensing element on its tip. The sensing element can
take a point measurement indicative of the flow in a part of the
duct at a point in time. However, because the flow in the duct is
unknown (varying both in profile across the cross-section of the
duct and with time), several measurements must be taken at
different points in the cross-section of the duct and at different
times. An average can then be built up which would approximate the
average flow rate. Its accuracy is limited by the difficulty in
aligning the sensing element correctly along the axis of the
duct.
[0006] In order to obtain reasonably accurate results, the prior
art insertion technique requires that measurements be taken at
several positions across at least one diameter of the duct.
However, it has been found that in practice where flow profiles are
distorted, it is necessary to measure across more than one diameter
(i.e., two orthogonal diameters) to provide sufficiently accurate
results which can be used for calibration. This introduces severe
problems when the duct system is installed underground, as it
requires that a large chamber be excavated around the duct in order
to allow access for separate circumferentially spaced holes in the
duct to be made to allow the orthogonal measurements to be made.
Additional problems may be encountered with duct systems installed
in aircraft where access may also be difficult.
[0007] A further problem with the prior art technique is that the
surface area of the rod which supports the sensing element forms a
variable blockage in the duct as the element is moved across the
diameter. This blockage affects the results by altering the flow
profile in the duct and increases turbulence. Furthermore, the
process of taking the many measurements required is subject to
variability due to the often difficult operating conditions in
which the measurements must be made. For example, the insertion
probe operator may be working in a water filled, muddy pit which
makes it difficult to obtain the various readings with any certain
degree of accuracy.
[0008] Several different sensor configurations have also been used
including: 1) direct measurement of a propagation time of a pulse
emitted by a first transducer and received by a second transducer,
where the change in time is a function of fluid flow rate; 2) dual
"sing-around" sound velocimeters, where the difference in
"sing-around" frequency between the velocimeters is a function of
the fluid flow rate; 3) sensors producing continuous waves using
two widely different high frequency carriers but commonly modulated
with another much lower frequency signal, where the phase
difference of the modulated signal on the received carriers is a
function of the fluid flow rate; and 4) sensors producing bursts of
continuous waves, using a single frequency on a pair of
transducers, the burst duration being less than the acoustic
propagation time between the transducers, where the time between
the received transmissions is a function of flow rate.
[0009] Transit-time ultrasonic flow sensors, also known as
"time-of-flight" ultrasonic flow sensors, detect the acoustic
propagation time difference between upstream and downstream
ultrasonic transmissions, resulting from movement of flowing fluid,
and process this information to derive a fluid flow rate.
[0010] Transducers of transit-time ultrasonic flow sensors are most
often field mounted. They are generally individually attached to
the outside of a pipe. Unlike other types of ultrasonic flow
sensors, such as Doppler ultrasonic flow sensors, transit-time
ultrasonic flow sensors typically do not require placing a
transducer inside a pipe in order to make a flow measurement.
However, measurement accuracy may be compromised by a multitude of
factors, such as pipe wall integrity, pipe surface condition, and
distance between transducers.
[0011] Even when the transducers are in contact with the fluid
being measured (wetted), the transducers may become misaligned,
i.e., disposed at the wrong distance or angle, resulting in
measurement error. Thus, sensors having wetted transducers are
typically equipped with supporting electronics that include
sophisticated diagnostics for confirming proper installation and
operation. Consequently, such sensors are relatively expensive and
have a reputation for occasionally producing erroneous
measurements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates an ultrasonic flow sensor and a
reflecting surface according to an embodiment of the present
invention;
[0013] FIG. 2 illustrates an ultrasonic flow sensor with angled
transducers and a reflecting surface according to an embodiment of
the present invention;
[0014] FIG. 3 illustrates an ultrasonic flow sensor, a first
reflecting surface, and a second reflecting surface according to an
embodiment of the present invention;
[0015] FIG. 4 illustrates an ultrasonic flow sensor including an
end cap according to an embodiment of the present invention;
[0016] FIG. 5 illustrates an ultrasonic sensor system according to
an embodiment of the present invention;
[0017] FIG. 6 illustrates an ultrasonic sensor installed into an
existing duct assembly according to an embodiment of the present
invention;
[0018] FIG. 7 illustrates an ultrasonic flow sensor including an
end cap according to an embodiment of the present invention;
[0019] FIG. 8 illustrates a retrofit assembly including a boot
structure with a mounting flange according to an embodiment of the
present invention;
[0020] FIG. 9 illustrates a flow chart diagram for a method of
installing an ultrasonic sensor into an existing duct assembly
according to an embodiment of the present invention;
[0021] FIG. 10 illustrates a graph of wave speed versus
temperature; and
[0022] FIG. 11 illustrates a measurement of cavitation effects.
DETAILED DESCRIPTION
[0023] Reference in the specification to "one embodiment", "an
embodiment", or "another embodiment" of the present invention means
that a particular feature, structure or characteristic described in
connection with the embodiment is included in at least one
embodiment of the present invention. Thus, appearances of the
phrase "in one embodiment" or "according to an embodiment"
appearing in various places throughout the specification are not
necessarily all referring to the same embodiment. Likewise,
appearances of the phrase "in another embodiment" or "according to
another embodiment" appearing in various places throughout the
specification are not necessarily referring to different
embodiments.
[0024] Referring to FIG. 1, embodiments of the present invention
are directed to an ultrasonic sensor 100 adapted to be inserted
into a duct 130, the ultrasonic sensor 100 having ultrasound
transducers 105, 110 and being able to perform at a single site of
introduction into the duct 130. The flow sensor measures a forward
ultrasonic path transit time having a component of travel of
ultrasound in a forward direction relative to a fluid flow 155,
i.e., an axial direction relative to the region of the duct 130
where the sensor 100 is inserted, and also being able to perform a
second reverse path transit time measurement having a component of
travel of ultrasound in a second axial direction opposite to the
first axial direction, the arrangement being such that a comparison
of the signal associated with ultrasound travel in one axial
direction with that of the signal associated with ultrasound travel
in the opposite axial direction enables the flow rate of fluid in
the duct to be determined.
[0025] In addition, the ultrasonic sensor 100 may also be used to
measure the temperature of a moving or stationary fluid by using
either the transit time measurement in the forward direction or the
transit time measurement in the reverse direction. This results
from the fact that there exists a linear relationship between the
wave speed of an acoustic signal in a fluid and the temperature of
the fluid. The acoustic wave speed is equal to the distance
traveled divided by the transit time of an acoustic signal, wherein
the distance traveled is a distance between the transmitter and
receiver, and the transit time is a parameter measured by the
ultrasonic sensor 100. The temperature of a fluid may be calculated
by using the following equation:
T.sub.2=-1/M(V.sub.2-V.sub.1)+T.sub.1
[0026] T.sub.2=Temperature of a fluid at Acoustic Wave Velocity
V.sub.2
[0027] T.sub.1=Temperature of a fluid at Acoustic Wave Velocity
V.sub.1
[0028] M=fluid medium dependent Constant
[0029] Referring to FIG. 10, to measure the temperature of a known
fluid, for example MIL-H-5606 Hydraulic Oil, a graph is created
plotting wave speed versus temperature of the fluid based on data
obtained experimentally for various wave speed and temperature
values. Using the equation for a line Y=mX+B, where Y in this case
equals a measured wave speed value, m equals the slope of the line,
X equals the temperature to be determined, and B equals the Y
intercept point, and solving for X, the temperature is:
X=(Y-B)/m
X=(4896.9-5425.4)/-5.2855=100.degree. F.
[0030] The ultrasonic sensor 100 may also be used to measure the
viscosity of a moving fluid by using either the transit time
measurement in the forward direction or the transit time
measurement in the reverse direction. As discussed above, the
temperature may be calculated using the transit time. The viscosity
of a fluid is proportional to the temperature of the fluid.
Therefore, using the appropriate calculation, the viscosity may be
calculated using the temperature measurement of the fluid.
[0031] The viscosity of a fluid may be calculated by using the
following equation:
V=KT
[0032] K=Constant factor for a particular fluid
[0033] T=Temperature of a fluid at Acoustic Wave velocity
[0034] Finally, the ultrasonic sensor 100 may also provide a
measurement of the cavitation of a moving fluid. Air entrainment
(cavitation) may be indicated by erratic signal patterns and
reduced received signal strength. Changes in signal strength for a
given flow rate indicates a 2-phase flow, i.e., the signal strength
is proportional to the % of gas bubbles in a flowing fluid. The %
of gas bubbles in a flowing fluid indicates the degree of
cavitation. For example, as illustrated in FIG. 11, a forward
traveling signal received at a receiving transducer that varies in
strength from 65% to 30% indicates cavitation effects, wherein the
variation in the signal strength indicates the degree of
cavitation.
[0035] The ultrasonic sensor 100 requires at least one ultrasound
transmitter and detector pair 105, 110 for each forward or reverse
measurement. Embodiments of the present invention use the same
transducer 105, 110 to transmit and detect. Therefore, two
transducers 105, 110 each capable of transmitting and detecting may
measure both the forward and the reverse transit times.
[0036] Embodiments of the present invention may use piezoelectric
transducers to generate or receive the acoustic signals.
Piezoelectric transducers, in the case of a receiver, convert force
or mechanical stress into electric charge which in turn may be
converted into a voltage. Conversely, if a voltage is applied to a
piezoelectric transducer the resultant electric field will cause a
deformation of the crystal material to generate an acoustic signal.
The frequency range of the ultrasound signals may be up to 5
MHz.
[0037] The first transducer 105 may comprise the transmitter of one
forward path transmitter/receiver pair and the receiver of another
reverse transmitter/receiver pair. The second transducer 110 may
comprise the receiver of the forward transmitter/receiver pair and
the transmitter of the reverse transmitter/receiver pair.
[0038] Referring to FIG. 4, the two transducers 105, 110 are
mounted and spaced apart by a distance L.sub.1 within a housing
111. An end cap 115 is hermetically sealed to the housing 111 to
enclose and isolate the transducers 105, 110 from the flowing fluid
155. A distance L.sub.2 between the end cap surface 116 in contact
with the flowing fluid 155 and the emitting surface of the
transducers 105, 110 is equal to (n/2).lambda., where .lambda. is a
wavelength of the transmitted signal, and n is an integer. For
example, resonance transmission of an acoustic signal occurs for
n=1 and L.sub.2=1/2 .lambda.. A distance L.sub.3 between the end
cap surface 116 in contact with the flowing fluid 155 and a point
on the housing 111 located between the transducers 105, 110 is
equal to (3/4+n/2).lambda., where .lambda. is a wavelength of the
transmitted signal, and n is an integer. For example, resonance
reflection of an acoustic signal occurs for n=2 and L.sub.3=1.75
.lambda..
[0039] Referring to FIG. 1, the ultrasonic sensor 100 is adapted to
measure the transit times of an ultrasonic pulse in the forward and
reverse directions of a W shaped path 190 or a V shaped path 191.
The transit time difference in the forward and reverse directions
of ultrasound travel along the W paths 190 or V paths 191 may be
used to calculate the flow rate of fluid in the duct 130. In
addition, the temperature, viscosity, and cavitation of the fluid
may be calculated using the transit time in the forward direction
or the transit time in the reverse direction.
[0040] To calculate the flow rate from the transit times along each
W shaped 190 or V shaped 191 transmission path, the difference
between the transit times in the directions along the paths in the
forward and reverse times may be used. An approximately
proportional relationship exists between transit time and flow. For
example, for a V shaped path:
V=K*D/sin 2.THETA.*1/(T.sub.o-.tau.).sup.2*.DELTA.T
[0041] Where:
[0042] V=mean velocity of flowing fluid
[0043] K=constant
[0044] D=inner diameter of pipe or duct
[0045] .THETA.=incident angle of ultrasonic signal
[0046] T.sub.o=Zero flow transit time
[0047] .DELTA.T=T.sub.2-T.sub.1
[0048] T.sub.1=transit time of acoustic signal from upstream
transducer to downstream transducer
[0049] T.sub.2=transit time of acoustic signal from downstream
transducer to upstream transducer
[0050] .tau.=transit time of acoustic signal through pipe or duct
wall and lining
[0051] In addition to the above formula, the flowing fluid velocity
(V.sub.f) can be determined by the following equation:
V.sub.f=Kdt/T.sub.L
[0052] where K is a calibration factor for the volume and time
units used, dt is the time differential between upstream and
downstream transit times, and T.sub.L is the zero-flow transit
time. Theoretically, transit-time ultrasonic meters can be very
accurate (inaccuracy of .+-.0.1% of reading has been reported). The
error in these measurements is limited by both the ability of the
signal processing electronics to determine the transit time and by
the degree to which the electrical signal used to generate the
acoustic signal is constant, i.e., a sonic velocity (C) that is
constant. The speed of sound in the fluid is a function of the
stability of the electrical signal used to generate the acoustic
signal, the density of the fluid and the temperature of the
fluid.
[0053] Therefore, relatively simple electronic circuitry may be
employed to extract flow data, temperature data, and cavitation
data. For example, an electronic transmitting and receiving device
400 may be used, connected to the transducers 105, 110 via wires
112 which pass through the housing 111 and may be sealed by epoxy.
The electronics 400 may be connected after the ultrasonic sensor
100 is inserted (see FIG. 4).
[0054] Preferably the ultrasonic sensor 100, i.e., the transducer
pair 105, 110 contained within the end cap 115, are adapted to be
flush with a wall of the duct 130 in use. This reduces the
disturbance of the fluid flow to provide a higher accuracy
measurement of the fluid flow rate (see also FIG. 5).
[0055] Because the ultrasound path has at least two path
environments (forward and reverse W paths 190, or forward and
reverse V paths 191) and because the ultrasound does travel through
the fluid in the duct axially (at least with an axial component)
rather than a single point measurement of flow being obtained as in
the prior art, the fluid flow at several different points on the
ultrasound path affects the signal that is measured. This provides
a degree of built-in averaging or integration which eliminates the
need to obtain many measurements at different points in the
cross-section of the duct. Therefore, an amount of integration of
the signal is inherently present, which provides a more accurate
indication of flow rate than single point measurements. In
addition, because there is no need to make measurements at
different points, the sensor does not need to be moved, which
simplifies the operation. A longer acoustic path provides a more
accurate indication of flow rate. Therefore, a W shaped path
provides a more accurate indication of flow rate than does a V
shaped path.
[0056] Referring to FIG. 1, preferably, the ultrasonic sensor 100
is adapted to use the reflection of the ultrasound off of a
reflecting surface 120 on a wall of the duct 130 and a reflective
surface 116 of the end cap 115 to create the forward W shaped
ultrasonic path 190 and the reverse W shaped ultrasonic path 190.
The ultrasonic paths are beams of ultrasound. The ultrasonic sensor
100 operates to take the forward and reverse ultrasonic path
measurements from a stationary position. In addition, because there
is no need to make measurements at different points, the sensor
does not need to be moved, which simplifies the operation.
[0057] In embodiments of the present invention the first 105 and
second 110 transducers may be oriented at an angle .alpha. 157
relative to an axis 150 orthogonal to a central axis 156 of the
duct 130. The choice of length L.sub.1 between the first transducer
105 and second transducer 110 is dependent upon the diameter of the
duct and orientation angle .alpha. 157 of the transducers 105, 110.
In use, signals are transmitted along paths between the transducers
105, 110, and in order for the first and second transducers 105,
110 to communicate when used in, for example, a circular duct 130,
the relation L.sub.1=3 tan .alpha. D is preferable, where D is the
duct diameter and .alpha. 157 is the angle of inclination of the
acoustic paths relative to axis 150 orthogonal to the central axis
156 of the duct 130. This relationship arises because of the angle
of reflection of the signal from the duct wall or walls.
[0058] As an example, given a duct diameter D=10 inches, if the
angle of inclination .alpha. 157 is one degree, the signal path is
one degree relative to axis 150 orthogonal to the central axis 156
of the duct 130, and the separation L.sub.1 between the first
transducer 105 and second transducer 110 is equal to approximately
{fraction (1/2)} inch. From the above, the length L.sub.1 should be
correctly set for different duct diameters and should be adjustable
if the sensor assembly is to be suitable for use with any duct
diameter.
[0059] FIG. 1 illustrates a W path according to a first embodiment
of the present invention. The ultrasonic sensor 100 may comprise
first and second transducers 105, 110 with a reflecting surface 120
located on a duct 130 wall opposite the transducers. The
transducers 105, 110 are oriented at an angle .alpha. 157
approximately equal to zero relative to the axis 150 orthogonal to
the central axis 156 of the duct 130. That is, the initial path is
in effect orthogonal to the duct axis. However, due to the
diffraction of the acoustic signal as it leaves a transducer, the
pair of transducers 105, 110 need not be absolutely adjacent one
another (i.e. L.noteq.0). In this embodiment, the first and second
transducers 105, 110 launch the acoustic signal at an angle .alpha.
157 approximately equal to zero, the acoustic signal impinges upon
a reflecting surface 120 located on the duct 130 wall opposite the
transducers 105, 110. Specifically, the first transducer 105
launches a forward traveling acoustic signal at an angle .alpha.
157 approximately equal to zero into the duct 130 which propagates
through a forward traveling fluid 155 contained in the duct 130
until the acoustic signal reflects off the reflecting surface 120.
A portion of the acoustic signal is then re-directed back towards
the flow sensor 100 until it makes a second reflection off the end
cap surface 116. Specifically, a portion of the acoustic signal
reflects at a reflection point 117 on the end cap 115 surface
located midway between the central axis of the first 105 transducer
and the central axis of the second 110 transducer. The acoustic
signal is then re-directed back towards the reflecting surface 120
to make a third reflection off the reflecting surface 120. Again, a
portion of the acoustic signal is then re-directed back towards the
flow sensor 100 until it then passes through the end cap surface
116 to reach the second transducer 110 also oriented at an angle
.alpha. 157 equal to zero.
[0060] The reverse W path 190 is similar. The second transducer 110
launches a reverse traveling acoustic signal into the duct 130
which propagates through a forward traveling fluid 155 contained in
the duct 130 until the acoustic signal reflects off the reflecting
surface 120. The acoustic signal is then re-directed back towards
the flow sensor 100 until it makes a second reflection off the end
cap surface 116. This reflection takes place at the reflection
point 117 on the end cap surface 116 located midway between the
central axis of the first 105 transducer and the central axis of
the second 110 transducer. The acoustic signal is then re-directed
back towards the reflecting surface 116 to make a third reflection
off the reflecting surface 116. Again, the acoustic signal is then
re-directed back towards the flow sensor 100 until it then passes
through the end cap surface 116 to reach the first transducer
105.
[0061] FIG. 2 illustrates an alternative embodiment of the present
invention. The first 205 and second 210 transducers are oriented at
an angle .alpha. 257 relative to the axis 150 orthogonal to the
central axis 116 of the duct 130. The first transducer 205 launches
a forward traveling acoustic signal at an angle .alpha. 257 into a
duct 130 which propagates through a forward traveling fluid 155
contained in the duct 130 until the acoustic signal reflects off a
reflecting surface 120 located on a duct 130 wall opposite the
transducers 205, 210 at a reflection angle approximately equal to
.alpha. 257. The acoustic signal is then re-directed back towards
the flow sensor 200 until it makes a second reflection off the end
cap surface 116. This reflection takes place at a reflection point
117 on the end cap 115 located midway between the central axis of
the first 205 transducer and the central axis of the second 210
transducer and also occurs at an angle .alpha. 257. The acoustic
signal is then re-directed back towards the reflecting surface 120
to make a third reflection off the reflecting surface 120. Again,
the acoustic signal is then re-directed by the reflecting surface
120 back towards the flow sensor 200 until it then passes through
the end cap surface 116 to reach the second transducer 210 also
oriented at an angle .alpha. 257.
[0062] The reverse W path 190 is similar. The second transducer 210
launches a reverse traveling acoustic signal at an angle .alpha.
257 into the duct which propagates through the forward traveling
fluid 155 contained in the duct 130 until the acoustic signal
reflects off the reflecting surface 120. The acoustic signal is
then re-directed back towards the flow sensor 200 until it makes a
second reflection off the end cap surface 116. This reflection
takes place at the reflection point 117 located on the end cap 115
midway between the central axis of the first 205 transducer and the
central axis of the second 210 transducer. The acoustic signal is
then re-directed back towards the reflecting surface 120 to make a
third reflection off the reflecting surface 120. Again, the
acoustic signal is then re-directed back towards the flow sensor
200 until it then passes through the end cap surface 116 to reach
the first transducer 205.
[0063] FIG. 3 illustrates a further embodiment of the present
invention. The ultrasonic flow sensor 300 may comprise first 105
and second 110 transducers with first 321 and second 322 reflecting
surfaces, where the transducers 105, 110 are oriented at an angle
.alpha. approximately equal to zero relative the axis 150
orthogonal to the central axis 156 of the duct 330, i.e., the
initial path is in effect orthogonal to the duct axis 156. However,
the pair of transducers 105, 110 need not be adjacent one another
(i.e. L.sub.1.noteq.0). In this embodiment, the first 105 and
second 110 transducers launch acoustic signals at an angle .alpha.
approximately equal to zero, the acoustic signals impinge upon
first 321 and second 322 reflecting surfaces each oriented at an
angle .beta. 357 relative the axis 150 orthogonal to the central
axis 156 of the duct 330.
[0064] Specifically, the first transducer 105 launches a forward
traveling acoustic signal at an angle .alpha. approximately equal
to zero into the duct 330 which propagates through a forward
traveling fluid 155 contained in the duct 330 until the acoustic
signal reflects off a first reflecting surface 321 oriented at an
angle approximately equal to .beta. 357. The acoustic signal is
then re-directed back towards the flow sensor 300 until it makes a
second reflection off the end cap surface 116. This reflection
takes place at the reflection point 117 located on the end cap 115
midway between the central axis of the first 105 transducer and the
central axis of the second 110 transducer and also occurs at an
angle .beta. 357. The acoustic signal is then re-directed back
towards a second reflecting surface 322 to make a third reflection.
The acoustic signal reflects off the second reflecting surface 322
also oriented at an angle approximately equal to .beta. 357. Again,
the acoustic signal is then re-directed back towards the flow
sensor 300 until it then passes through the end cap surface 116 to
reach the second transducer 110 also oriented at an angle .alpha.
equal to zero.
[0065] The reverse W path 190 is similar. The second transducer 110
launches a reverse traveling acoustic signal into a duct 330 which
propagates through the forward traveling fluid 155 contained in the
duct 330 until the acoustic signal reflects off the second
reflecting surface 322. The acoustic signal is then re-directed
back towards the flow sensor 300 until it makes a second reflection
off the end cap surface 116. This reflection takes place at the
reflection point 117 located on the end cap 115 midway between the
central axis of the first 105 transducer and the central axis of
the second 110 transducer. The acoustic signal is then re-directed
back towards the first reflecting surface 321 to make a third
reflection. Again, the acoustic signal is then re-directed back
towards the flow sensor 300 until it then passes through the end
cap surface 116 to reach the first transducer 105.
[0066] The reflecting surface 120 as shown in FIG. 1 and FIG. 2, as
well as the first reflecting surface 321 and second reflecting
surface 322 as shown in FIG. 3, may be machined or formed into an
interior surface during the initial fabrication of, e.g., a duct, a
manifold, or a pipe. Alternatively, the reflecting surface 120, or
the first reflecting surface 321 and second reflecting surface 322
may be machined into an interior surface of, e.g., an existing
duct, manifold, or pipe in a "retrofit" process.
[0067] FIG. 5 illustrates an ultrasonic sensor system 500
consisting of a duct assembly 510, an ultrasonic sensor 100, a
reflecting surface 120, or first reflecting surface 321 and second
reflecting surface 322, and connectors 520. Ultrasonic sensor
system 500 may be adaptable to an existing fluid system. Connectors
520 may be any type of mating connector that will provide a fluid
tight seal, for example, with an existing fluid system. The
reflective surface 116 of the end cap 115 is flush with an interior
surface 512 of the duct assembly 510. This prevents any disturbance
of a fluid flowing through the duct assembly 510. Reflecting
surface 120, or first reflecting surface 321 and second reflecting
surface 322, may be machined into an interior surface 511 of the
duct assembly 510 during the fabrication of duct assembly 510.
[0068] FIG. 6 illustrates an ultrasonic sensor 100 installed into
an existing duct assembly 610. Reflecting surface 120 or first
reflecting surface 321 and second reflecting surface 322 may be
machined into an interior surface 611 of duct assembly 610 during a
"retrofit" installation of ultrasonic sensor 100 into duct assembly
610. Referring to FIG. 6 and FIG. 7, ultrasonic sensor 100 may
include a standardized mounting flange 192 including four mounting
holes 193 to accommodate four mounting screws 194. The standardized
mounting flange 192 replicates the mounting flange used on existing
standardized fluid sensors. This aids in the retrofit process
wherein an existing standardized fluid sensor may be removed and
replaced by an ultrasonic sensor 100, the end cap 115 of ultrasonic
sensor 100 fitting into the existing hole in the duct assembly 610
after removal of the existing standardized fluid sensor.
[0069] Referring to FIG. 8, the retrofit installation may require
the machining of a reflecting surface 120 or first reflecting
surface 321 and second reflecting surface 322 into an interior
surface 611 of duct assembly 610. A retrofit assembly 650 that may
include precision machining equipment and a boot structure 651 with
a mounting flange 652 mounts to the existing hole pattern in the
duct assembly 610. The boot structure 651 serves to contain the
metal shards created during a machining process preventing
contamination of the existing duct assembly 610 during the retrofit
process. Accurate alignment of the retrofit assembly 650 may be
achieved by using the mounting flange 652 in conjunction with the
existing mounting holes in the duct assembly 610. A substantially
flat reflecting surface 120 or substantially flat first reflecting
surface 321 and second reflecting surface 322 may be machined into
an interior surface 611 of duct assembly 610 using precision
machining equipment that may be contained within the retrofit
assembly 650.
[0070] FIG. 9 illustrates a flow chart diagram for a method of
installing an ultrasonic sensor into an existing duct assembly. An
existing fluid sensor is first removed 910 from an existing duct
assembly. A retrofit assembly 650 that may contain precision
machining equipment and a boot structure 651 with a mounting flange
652 is mounted 920 to the existing hole pattern in the duct
assembly 610 using four bolts through the four bolt mounting flange
652 into the existing four mounting holes. The precision machining
equipment that may be contained within the retrofit assembly is
inserted 930 through the existing hole in the duct assembly 610 to
machine the reflecting surface 120, 321, 322. Any metal shards
created during the machining process are contained within the boot
structure 651. The precision machining equipment is withdrawn from
the existing hole in the duct assembly 610 and a vacuum source that
may also be contained within the retrofit assembly 650 is used to
remove 940 the metal shards from the boot structure 651. An
ultrasonic sensor 100 is then installed 950, the end cap 115 of
ultrasonic sensor 100 fitting into the existing hole in the duct
assembly 610. The standardized mounting flange 192 including four
mounting holes 193 accommodates four mounting screws 194 secured to
the duct assembly 610.
[0071] While the description above refers to particular embodiments
of the present invention, it will be understood that many
modifications may be made without departing from the spirit
thereof. The accompanying claims are intended to cover such
modifications as would fall within the true scope and spirit of an
embodiment of the present invention. The presently disclosed
embodiments are therefore to be considered in all respects as
illustrative and not restrictive, the scope of an embodiment of the
invention being indicated by the appended claims, rather than the
foregoing description, and all changes that come within the meaning
and range of equivalency of the claims are therefore intended to be
embraced therein.
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