FLUID FLOW SENSOR

Abstract: A flow sensor for regulating the air flow rate to a cooling system can be formed as a housing (10, 12) for channeling the flow through a rectangular cavity (16) and a one piece vane (22) of bent metal strip which deflects and closes an electrical contact (30) at a predetermined air flow rate and opens when the air flow rate falls below a preset threshold level.

Description: This invention pertains to a fluid flow sensor for sensing the flow of fluids, in particular to an air flow sensor having high sensitivity at low air flow rates for cooling systems. Many complex machines used in modern industry have numerous sophisticated components which generate heat but can be easily damaged if the temperature of the component is too high. Automatic cooling is extensively used in such machines to prevent temperature rise. Flow sensors are used in a variety of systems to measure, regulate or control the flow of fluids. An important application of such sensors is to insure that the flow of cooling fluids to a sensitive component does not drop to the point where the component is damaged. Such a fluid flow sensor would therefore measure the flow rate and compare it to a preset threshold. If the flow rate drops below the threshold, and electrical signal is sent to the controls of the system to take predetermined corrective action before serious damage occurs. In sophisticated industrial machines, space is at a premium. Such sensors must be kept small, inexpensive, rugged and sensitive. In the prior art there are flow sensors which use balls inside transparent tubes. The air flow in the tube must be upward to oppose gravity. The ball rests on a support when there is no flow or low flow. A sufficient flow rate causes the ball to rise to a level where the position of the ball is detected by a light source and light sensor. Ths type of sensor is large, fragile and suitable for use in one position only. Another type of sensor uses a magnet attached to a spring inside the air flow tube. A reed switch outside the tube detects the movement of the magnet due to a change in flow. Friction between the magnet and the walls of the tube causes the flow rate at which the switch is closed to differ from the flow rate at which it is opened by 50%. There are also flap switches in the prior art which use a hinged flap inside the flow to trigger a microswitch. The mechanical linkage, again, causes friction which causes great differences between the flow rate at which the switch is opened and the flow rate at which it is closed. FR-A-1308963 discloses a straight flexible blade which extends across the flow channel and is bent by the flow to make and break electrical contacts, as is set out in the introductory clause of the present claim 1. DE-A-2620460 discloses another straight flexible blade which extends beside a main flow channel in which a deflector deflects flow along a subsidiary path across which the blade extends to deflect it as in the French reference. The invention has a flexible blade which is bent in its rest position, as is set out in the characterising clause of claim 1. The sensor can be made sensitive by keeping the flexible material thin, but insenstive to oscillations by making the outer extremity of the vane thicker and heavier. This sensor can be made quite small, less than 5 cm on its longest side, and quite sensitive, less than 10% change in flow is required between interruption and recontact or closing. The sensor also has a very small pressure drop across it, approximately 7000Pa and operates in any orientation. The sensor can work well in a low flow régime, 0.14 to 1.4 cubic metres per how at standard temperature and pressure and where flow is laminar and is rugged and inexpensive. Examples of the invention will now be described with reference to the accompanying drawings in which:- Figure 1 is a top view in partial section of a sensor. Figure 2 is a side view of the sensor of Figure 1. Figure 3 is an end view of the sensor of Figures 1 and 2. Figure 4 is a perspective view of the vane of the sensor. Figure 5 is a sectional view of an alternative embodiment of the sensor. The illustrated sensor has a housing 10 preferably made of transparent hard plastic and a cover 12 of the same material. The cover 12 is attached to the housing 10 with approximately 6 screws 14. The attachment is sufficiently tight to form an air tight seal. Within the housing 10 there is formed an elongated cavity 16 which is approximately rectangular. At opposite ends of the cavity 16 there is provided an inlet hold 18 and outlet hole 20 with suitable fittings for attachment to an air flow line (not shown). Within the cavity 16 a vane assembly 22 of thin welded metal is attached to the housing 10 with screws 24 and nuts 26. A first electrical connection tab 28 is attached to one of the screws 24 on the outside of the housing 10 to provide an electrical connection point to the vane assembly 22. The holes in the housing 10 through which the screws 24 are passed are sufficiently large to clear the threads on the screws 24. A set screw 30 is attached to the housing 10 through a threaded hole in the housing. A second electrical connection tab 32 is held on with the set screw 30 with a nut 34. In operation, the sensor is connected serially in a fluid flow line. A pumping means (not shown) pumps fluid through the fluid flow line and the sensor. As the flow rate through the sensor is increased from zero, at some first limit point, called the flow rate at closing (or the flow rate at recontact), it becomes sufficient to elastically bend vane 22 to contact set screw 30, so that an electrical connection path is made from first tab 28 through screw 24, vane 22 and set screw 30 to second tab 32. If the flow rate is then decreased, at some second limit point less than the first limit point, the flow rate becomes insufficient to maintain contact between vane 22 and set screw 30 and the electrical connection between vane 22 and set screw 30 is interrupted as the vane elastically returns to the position shown in FIG. 1. In general, this second limit point, the flow rate at which this electrical connection is interrupted when the flow rate is decreasing, is called the threshold of the sensor. The threshold is preset to a desired level by adjusting set screw 30. The vane 22 functions in three ways. It is a leaf spring, it is an electrical path and it is a flow deflector. The vane 22 has three portions which together accomplish these functions. As shown in FIG. 4, the vane 22 is formed, a mounting portion 40, a contact portion 42 generally parallel to the mounting portion and a distal portion 44 formed at an angle to the contact portion. The vane may be formed of one strip of metal such as 0.005 cm thick type 302 stainless steel. The mounting portion 40 has holes 46 through which the vane 22 is mounted to the housing 10 with the screws 24. In the embodiment shown in FIG. 4, the contact portion 42 is offset from the mounting portion 40 to provide clearance from the housing 10 for the set screw 30. In an alternative embodiment shown in FIG. 5, the vane can be formed without the offset and the offset can be provided in the housing 10. To provide good sensitivity the set screw 30 is placed in the housing 10 at the end of the contact portion 42 nearest the distal portion 44. Also to provide good sensitivity, the length L1 of the distal portion 44 should be longer than the length L2 of the contact portion 42. We have found it best to make L1 approximately twice L2. To dampen fluttering of the distal portion 44 in the air flow, it is advantageous to make the distal portion 44 stiffer and more massive than the contact portion 42. This can be accomplished by fastening a thickening portion 48 to the distal portion 44. The thickening portion 48 can, for example, be a similar shaped sheet of the identical material and the fastening can be by spot welding at four attachment points 50. The attachment of the thickening portion 48 stiffens and increases the mass of the assembly and reduces the frequency of oscillation, thereby insuring crisp switch contacts. The sensor described has a very small delta. Delta here is taken to be the fractional difference between the flow rate at closing (or recontact) when contact is made between vane 22 and set screw 30 and the flow rate at interruption of contact. Symbolically, Δ = flow rate of closing - flow rate at interruption of contact flow rate of closing Because of internal friction, delta can be large in most prior art sensors. Let us consider a hypothetical example to show the importance of a small delta. The component to be protected requires a flow rate of 16 SCFH (1 SCFH = 0,028316 m³/h). If the threshold (the flow rate at interruption of contact) is set at 16 SCFH (1 SCFH = 0,028316 m³/h) and if the delta is 50%, the flow rate must be 32 SCFH (1 SCFH = 0,028316 m³/h) or above to ensure contact. Thus, with a high delta, an excessively high flow rate is necessary to operate the sensor. If the delta can be reduced to less than 10%, as in the invention, then the flow rate could be set as low as 18 SCFH (1 SCFH = 0,028316 m³/h) to make contact and be sure contact will be interrupted at slightly above 16 SCFH (1 SCFH = 0,028316 m³/h). While the invention has been described in one embodiment as a sensor for monitoring the flow rate of cooling air, the invention is not limited to such applications. For example, the sensor may be used to monitor the flow rate of a non-electrically conductive gas in a line which provides the gas to be bubbled through a solution. Similarly, the sensor can monitor the flow rate of non-conductive liquids as well as gases.

Claims: A fluid flow sensor comprising a body (10) having an internal cavity (16) and a first opening (18) for conveying fluid into the cavity, a second opening (20) for conveying fluid out of said cavity and a first electrical contact means (30) inside said cavity, a thin flexible vane (22) comprising a mounting portion (40), a contact portion (42) including a second electrical contact means (26,28) and a distal portion (44), said mounting portion being fixedly mounted to said body , said contact portion being intermediate said mounting portion and said distal portion, and arranged so that said fluid flowing through said cavity from said first opening to said second opening causes said vane elastically to bend so that said second electrical contact means contacts said first electrical contact means when said rate of flow of said fluid is above a first limit point and the contact between said second electrical contact means and said first electrical contact means is interrupted when the rate of flow of said fluid drops below a preset threshold level, first conduction means for conducting electricity between a point outside the body and said first electrical contact means, second conduction means for conducting electricity between a point outside the body and said second electrical contact means, characterised in that said mounting portion extends substantially parallel to a line of flow of said fluid from said first opening to said second opening, said contact portion extends generally parallel to said mounting portion when the rate of flow is zero and said distal portion of said vane is disposed at an angle relative to said contact portion so that it crosses the line of flow. A sensor as claimed in claim 1 wherein said preset threshold level is less than said first limit point, said first electrical contact means raining in contact with said second electrical contact means when said rate of flow decreases from above said first limit point until said rate reaches said preset threshold level. A sensor as claimed in claim 1 or claim 2 comprising means (48,50) for adjusting said threshold level. A sensor as claimed in any one of claims 1 to 3 wherein said distal portion is heavier than the contact portion. A sensor as claimed in any one of claims 1 to 4 wherein said distal portion is thicker than the contact portion. A sensor as claimed in any one of claims 1 to 5 wherein said distal portion is longer than the contact portion.

Inventors: HERTEL RICHARD J, KLOS LEO V, HERTEL, RICHARD JOHN, KLOS, LEO VINCENT
Applicants: VARIAN ASSOCIATES, VARIAN ASSOCIATES, INC.
Application year: 1989
Main classification: G01P13
IPC codes: G01F1, H01H35, G01P13