SENSOR FOR DETECTING PRESSURE FLUCTUATIONS IN A FLOWING FLUID, AND MEASUREMENT SYSTEM FORMED THEREWITH

Abstract

The sensor comprises a deformation element (111) that is flat at least in sections and has a planar surface (111+) and an opposite planar surface (111 #), a sensor lug (112) extending starting from the first surface (111+) of the deformation element, a connection sleeve (113) extending starting from the deformation element, a transducer element (12), which is arranged within the connection sleeve (113) and contacts the surface (111+) of the deformation element with a contact surface, for generating an electrical sensor signal representing temporally changing movements of the sensor lug and/or temporally changing deformations of the deformation element, as well as fastening means, which are positioned within the connection sleeve (113) and are mechanically connected thereto, for fixing the transducer element (12) in the connection sleeve (113). The fastening means (13) of the sensor according to the invention comprise a spring assembly (131) formed by means of at least two stacked disk springs, wherein the disk springs are elastically deformed by exerting a pressing force which holds the transducer element against the deformation element.

Claims

1-17. (canceled)

18. A sensor for detecting pressure fluctuations in a K?rm?n vortex street formed in a flowing fluid, the sensor comprising: a deformation element, which is membrane-like or disk-shaped, flat at least in sections, and made of a metal, including a planar first surface and an opposite planar second surface; a sensor lug, which is rod-shaped, planar or wedge-shaped, extending from the first surface of the deformation element; a connection sleeve made of a metal, which extends from the deformation element and is connected thereto in an electrically conductive manner; a transducer element, which is piezoceramic and at disk-shaped, disposed within the connection sleeve and contacting the second surface of the deformation element with a first contact surface in an electrically conductive manner as to generate an electrical sensor signal representing temporally changing, and at least temporarily periodic, movements of the sensor lug and/or temporally changing, and at least temporarily periodic, deformations of the deformation element; and and a fastener disposed within the connection sleeve and releasably, mechanically connected thereto and configured to releasably, fix the transducer element in the connection sleeve, wherein the fastener comprises a cylindrical spring assembly formed of at least two stacked disk springs, and wherein the disk springs are adapted to elastically deform by exerting a pressing force, which holds the transducer element against the deformation element, such that a minimum surface pressure acting on the transducer element is more than 1 MPa and/or a maximum surface pressure acting on the transducer element is less than 20 MPa, and/or such that a non-positive connection is formed between the transducer element and the deformation element.

19. The sensor according to claim 18, wherein the fastener comprises an inner screw sleeve including an external thread, and the connection sleeve comprises an inner thread in a distal end remote from the deformation element, and wherein the inner screw sleeve is screwed into the inner thread to form an abutment configured to contact the spring assembly.

20. The sensor according to claim 18, wherein the fastener comprises an inner locking ring and the connection sleeve comprises an inner groove in a region remote from the deformation element, and wherein the inner locking ring is inserted into the inner groove to form an abutment configured to contact the spring assembly.

21. The sensor according to claim 18, wherein the deformation element and the sensor lug are integrally bonded to each other; and/or wherein the transducer element and the deformation element are not integrally bonded to each other; and/or wherein the transducer element and the spring assembly are not integrally bonded to each other.

22. The sensor according to claim 18, wherein the fastener comprises a ring-shaped, insulating disk made of a ceramic and/or a plastic; and wherein the insulating disk is disposed between the transducer element and the spring assembly.

23. The sensor according to claim 18, wherein a minimum surface pressure acting on the transducer element is more than 1 MPa, especially more 3 MPa; and/or wherein a maximum surface pressure acting on the transducer element is less than 20 MPa, especially less than 15 MPa.

24. The sensor according to claim 18, wherein a minimum surface pressure acting on the transducer element is more than 3 MPa; and/or wherein a maximum surface pressure acting on the transducer element is less than 15 MPa.

25. The sensor according to claim 18, further comprising a metal foil disposed between the transducer element and the deformation element such that the foil facilitates an electrically conductive connection between the transducer element and the deformation element and/or facilitates a substantially uniform mechanical contact between the transducer element and the deformation element.

26. The sensor according to claim 18, wherein the transducer element contacts the deformation element and/or the connection sleeve in an electrically conductive manner.

27. The sensor according to claim 18, wherein at least one of: the disk springs of the fastener are made of a stainless steel or a nickel-based alloy; the disk springs of the fastener and the deformation element are made of a same material; the deformation element comprises a stainless steel or a nickel-based alloy; the sensor lug comprises a stainless steel or a nickel-based alloy; the connection sleeve comprises a stainless steel or a nickel-based alloy; the deformation element and the sensor lug comprise a same material; the deformation element and the connection sleeve compromise a same material; the deformation element and the sensor lug are portions of one and the same monolithic molded part; and the deformation element and the connection sleeve are portions of one and the same monolithic molded part.

28. The sensor according to claim 18, further comprising a compensating element, which is rod-shaped or planar or sleeve-shaped, extending from the second surface of the deformation element and configured to compensate forces and/or torques resulting from common movements of the deformation element and the sensor lug.

29. The sensor according to claim 28, wherein at least one of: the compensating element extends through the spring assembly such that a longitudinal, main axis of inertia of the compensating element and a longitudinal, main axis of inertia of the spring assembly extend parallel and coincident to each other, and/or such that the spring assembly and the compensating element do not contact each other; the deformation element and the compensating element are integrally bonded to each other; the sensor lug and the compensating element are arranged in alignment with each other; the compensating element and the deformation element are disposed and aligned with respect to each other such that a main axis of inertia of the deformation element extends as an extension parallel to a main axis of inertia of the compensating element and coincides therewith; the deformation element and the compensating element are parts of one and the same monolithic molded component such that the sensor lug, deformation element and compensating element are parts of said molded component, and/or such that the connection sleeve, deformation element and compensating element are parts of said molded component; the deformation element comprises a stainless steel or a nickel-based alloy; and the deformation element and the compensating element consist of a same material such that the sensor lug, deformation element and compensating element consist of the same material and/or the connection sleeve, deformation element and compensating element consist of the same material.

30. A measuring system for measuring at least one flow parameter that is variable over time of a flow velocity, a volumetric flow, and/or a mass flow rate, of a fluid flowing in a pipe, the measuring system comprising: the sensor according to claim 18 configured to detect pressure fluctuations in the flowing fluid by detecting pressure fluctuations in a K?rm?n vortex street formed in the flowing fluid; and a measuring electronics electrically connected to the transducer element of the sensor, the measuring electronics configured to receive the sensor signal from the sensor and to process sensor signal as to generate measurement values representing the at least one flow parameter.

31. The measurement system according to claim 30, further comprising a tube configured to be inserted into a course of the pipeline, the tube including a lumen adapted to guide the fluid flowing in the pipeline, wherein the sensor is disposed in the tube such that the first surface of the deformation element faces the lumen of the tube and such that the sensor lug projects into the lumen.

32. The measurement system according to claim 30, further comprising a tube configured to be inserted into a course of the pipeline, the tube including a lumen adapted to guide the fluid flowing in the pipeline, wherein a wall of the tube including an opening, the opening including a socket configured to hold the deformation element on the wall, and wherein the sensor is disposed in the opening such that the deformation element covers and hermetically seals the opening and such that the first surface of the deformation element faces the lumen of the tube, wherein the sensor lug projects into the lumen.

33. The measurement system according to claim 31, further comprising a resistance element disposed in the lumen of the tube upstream of the sensor, relative to a direction of flow of the fluid, which resistance element is configured to generate about a K?rm?n vortex street in the flowing fluid.

34. The measurement system according to claim 31, wherein the sensor lug has a length measured as a minimum distance between a proximal end of the sensor lug, which proximal end adjoins the deformation element, to a distal end of the sensor lug, which distal end is remote from the deformation element or the first surface of the deformation element, wherein the length corresponds to less than 95% of a caliber of the tube and/or more than one half of the caliber of the tube.

35. A method comprising: measuring a flow parameter of a fluid flowing in a pipeline using the measurement system according to claim 29, wherein the flow parameter is at least one of a flow velocity, a volume flow rate and a mass flow rate, wherein a temperature of the fluid is at least temporarily more than 200? C., and/or wherein the fluid acts, at least temporarily, with a pressure of more than 100 bar on the deformation element and/or the sensor lug of the sensor.

36. The method of claim 34, wherein the fluid is steam.

Description

[0049] FIGS. 1, 2 show various schematic views of an exemplary embodiment of a measurement system, in this case in the form of a vortex flow meter, having a sensor and measurement electronics for measuring at least one flow parameter of a fluid flowing in a pipeline;

[0050] FIG. 3 schematically shows, in a cut-away side view, an exemplary embodiment of a sensor suitable for use in a measurement system according to FIG. 1 or 2;

[0051] FIGS. 4a, 4b schematically show, in two different side views, an exemplary embodiment of a sensor according to FIG. 3 suitable transducer element.

[0052] FIGS. 1 and 2 show an exemplary embodiment of a measurement system for measuring at least one flow parameter, possibly also variable over time, such as a flow velocity v and/or a volume flow rate V, a fluid flowing in a pipeline, for example a hot gas having, especially, at least temporarily a temperature of more than 200? C., and/or being at least temporarily under a high pressure, especially, of more than 100 bar. The pipe can be designed, for example, as a plant component of a heat supply network or of a turbine circuit, and therefore the fluid can be, for example, steam, especially saturated steam or superheated steam, or else, for example, a condensate discharged from a steam line. However, fluid can also be, for example, (compressed) natural gas or a biogas, so that the pipe can also be a component of a natural gas or biogas plant or of a gas supply network, for example.

[0053] The measurement system has a sensor 1, shown again enlarged in FIG. 3, which is provided or configured to detect pressure fluctuations in the fluid flowing past the sensor in a (main) flow direction and to convert it into a sensor signal s1 corresponding to said pressure fluctuations, for example, an electrical or optical sensor signal s1. As is apparent from FIGS. 1 and 2 when viewed together, the measurement system furthermore comprises measurement electronics 2for example accommodated in a pressure-resistant and/or impact-resistant protective housing 20which is electrically connected to the sensor 1 or communicates with the sensor 1 during operation of the measurement system. The measurement electronics 2 is, especially, configured to receive and process the sensor signal s1, namely, for example, to generate measurement values X.sub.M representing the at least one flow parameter, i.e., for example, the flow velocity v or the volume flow rate V. The measurement values X.sub.M can, for example, be visualized in situ and/or be transmitted in a wired manner via a connected field bus and/or in a wireless manner via radio to an electronic data processing system, for example a programmable logic controller (PLC) and/or a process control station. The protective housing 20 for the measurement electronics 2 can, for example, be produced from a metal, such as stainless steel or aluminum, and/or by means of a casting method, such as an investment casting or die casting method (HPDC); it can however, for example, also be formed by means of a plastic molded part produced in an injection molding method.

[0054] As shown in FIG. 3 or as readily apparent from FIGS. 2 and 3 when viewed together, the sensor 1 comprises an, especially, membrane-like or disk-shaped deformation element 111 as well as a sensor lug 112 having a left-side first side face and a right-side second side face, which, starting from a first surface 111+ of the deformation element 111, extends up to a distal (free) end that is namely remote from the deformation element 111 or its surface 111+. The deformation element 111 further has a second surface 111 #, which is opposite the first surface 111+, for example at least partially parallel to the first surface 111+. The deformation element 111 and the sensor lug 112 can be, for example, parts of one and the same monolithic molded part that is cast or produced by an additive manufacturing process such as 3D laser melting, for example; however, the deformation element and the sensor lug can also be designed as individual parts that are initially separate from one another and are only subsequently integrally bonded to one another, namely, for example, welded or soldered to one another, and therefore produced from materials that can correspondingly be integrally bonded to one another. The deformation element 111 can consist at least partially, namely, for example, predominantly or completely, of a metal such as stainless steel or a nickel-based alloy. The sensor lug can likewise consist at least partially of a metal, namely, for example, stainless steel or a nickel-based alloy; the deformation element 111 and the sensor lug 112 can especially also be produced from the same material. The deformation element 111 and the sensor lug 112 are moreover, especially, configured to be excited to, typically forced, oscillations about a common static rest position in such a way that the sensor lug 112 executes pendular movements that elastically deform the deformation element 111 in a detection direction running substantially transversely to the aforementioned flow direction. The sensor lug 112 accordingly has a width, measured as a maximum extent in the direction of the flow direction, which is substantially greater than a thickness of the sensor lug 112, measured as a maximum lateral extent in the direction of the detection direction. Moreover, the sensor lug 112 can be designed, for example, as a wedge-shaped or also as a relatively thin planar plate, as is quite common with such sensors.

[0055] Apart from the sensor lug 112 and the deformation element 111, the sensor 1 furthermore has a connection sleeve 113 extending from a circular circumferential edge segment of the second surface 111 # of the deformation element, which edge segment extends, for example, circularly. In order to detect oscillations of the deformation element 111 and the sensor lug, the sensor furthermore has at least one, especially disk-shaped and/or piezoceramic, transducer element 12, which is arranged within the connection sleeve 113 and contacts the surface 111+ of the deformation element with a first contact surface, for generating an electrical sensor signal representing temporally changing, especially at least temporarily periodic, movements of the sensor lug and/or likewise temporally changing, especially at least temporarily periodic, deformations of the deformation element 111, for example with an electrical (alternating) voltage corresponding to the aforementioned movements.

[0056] As already mentioned, the sensor 1 or the measurement system formed therewith is, especially, also intended to be used in such measuring points, where in the fluid to be measured, for example due to condensation-induced water hammers (CIWH), extremely high hydrostatic pressures, namely pressures of more than 100 bar acting perpendicularly against the wall 3* of the tube and therefore acting likewise against the sensor, can occur temporarily, namely, for example, in hot steam applications with fluid temperatures of above 200? C. In order to, especially, releasably fix the transducer element 12 in the connection sleeve 112, on the one hand, and to achieve an as low as possible sensitivity of the sensor to pressure shocks and/or temperature fluctuations or to reduce measuring errors resulting from such high loads on the sensor during measurement of the at least one flow parameter with the measurement system formed with the sensor, on the other hand, the sensor according to the invention further comprises fastening means 13 positioned within the connection sleeve 112 and thus, especially releasably, mechanically connected thereto. In the sensor according to the invention, the fastening means 13 comprise a, for example cylindrical, spring assembly 131 (spring stack) formed by means of two or more plate springs stacked on top of one another, wherein the disk springs (in the installed state) are elastically deformed by exerting a pressing force which holds the transducer element against the deformation element, as a result of which a non-positive connection is formed between the transducer element and the deformation element; this, especially, such that a minimum surface pressure acting on the transducer element 12 is more than 1 MPa, especially more 3 MPa, and/or a maximum surface pressure acting on the transducer element 12 is less than 20 MPa, especially less than 15 MPa.

[0057] According to another embodiment of the invention, it is further provided for the disk springs and the deformation element to consist of a same material. Alternatively or additionally, the disk springs can advantageously be made of a metal, namely, for example, stainless steel or a nickel-based alloy such as X7 CrNiAl 17-7 (WsNr 1.4568, EN 10027-2:1992-09).

[0058] In order to prevent a lateral displacement of the transducer element 12 in the installation position relative to the deformation element 111 or to the connection sleeve 113, the connection sleeve 113 and the transducer element 12 can advantageously also be designed such that an inner diameter of the connection sleeve 113 in the region of the installation position of the transducer element substantially corresponds to an outer diameter of the transducer element corresponding thereto, namely, for example, that said inner diameter is larger only by an amount which barely allows for positioning the transducer element 12 on the deformation element 111. In order to facilitate positioning of the transducer element 12, the connection sleeve can further be designed such that it has a (smallest) inner diameter in a region above the transducer element 12 (positioned in the installed position), which is greater than a (largest) outer diameter of the transducer element, for example by more than 1 mm. In order to ensure correct orientation of the transducer element 12 in the installation position, not least also with regard to an electrical polarization of the ceramic forming the transducer element 12 or with regard to a correct position of positively (+) or negatively (?) polarized partial regions of the transducer element 12, the transducer element 12 and the connection sleeve 113 can also be shaped such that the transducer element 12 and the connection sleeve 113 have outer or inner contours that are complementary to each other, but nevertheless prevent an incorrect installation position of the transducer element, for example such that, as shown in FIGS. 4a and 4b or as apparent from those FIGS. when viewed together, the transducer element 12 has an outer contour with one or more straight sections 12a, and that the connection sleeve has an inner contour with straight sections corresponding to the above-mentioned straight sections of the transducer element 12.

[0059] According to a further embodiment of the invention, the fastening means 13 comprise an (inner) locking ring 132 and the connection sleeve 113 comprises, in a region remote from the deformation element 111, a corresponding annular or circumferential (inner) groove 113a, wherein the (inner) locking ring is inserted into the (inner) groove to form an abutment for the spring assembly. Alternatively or additionally, the fastening means 13 can also comprise an (inner) screw sleeve having an external thread, and the connection sleeve can comprise an inner thread in a distal end remote from the deformation element 111, such that the (inner) screw sleeve is screwed into the inner thread to form an abutment for the spring assembly 131.

[0060] By using such fastening means formed by means of a spring assembly 131 comprising disk springs, it is also possible, inter alia, to fix the transducer element 12 on the deformation element without the transducer element 12 and the deformation element 111 being or having to be integrally bonded to one another, and therefore, for example, the use of adhesives for connecting the transducer element 12 and the deformation element 111 can be dispensed with. Likewise, the spring assembly 131 and the transducer element 12 can also be bonded to one another in a non-integral manner, namely by avoiding an adhesive bond that would bond the spring assembly and transducer element to one another; therefore the use of adhesives can be dispensed with here, as well. On the other hand, the use according to the invention of the spring assembly 131, however, also makes it easily possible to position a metal foil, for example a silver foil, between the transducer element 12 and the deformation element 111, which foil serves to bring about an electrically good conductive connection between the transducer element 12 and the deformation element 111 and/or to bring about an as uniform as possible mechanical contact between the transducer element 12 and the deformation element 111.

[0061] Furthermore, it is also readily possible to place further elements of the fastening means 13 between the transducer element 12 and the spring assembly 131, namely, for example, electrically and/or thermally insulating disks and/or a contact disk for electrically connecting an electrical connecting line leading to the transducer element, for example in such a way that the contact disks contact a second contact surface of the transducer element opposite the previously mentioned first contact surface of the transducer element in an electrically conductive manner. According to a further embodiment of the invention, the fastening means accordingly comprise a, for example annular, insulating disk, especially made of a ceramic and/or a plastic, which is positioned between the transducer element 12 and the spring assembly 131, and/or the fastening means comprise a contact disk 133 with an electrical connecting line 14 connected thereto in an electrically conductive manner.

[0062] According to a further embodiment of the invention, the measurement system further comprises a tube 3 that can be inserted in the course of the aforementioned pipe and has a lumen 3 that is surrounded by a wall 3*, for example a metallic wall, of the tube and extends from an inlet end 3+ to an outlet end 3 # and is configured to guide the fluid flowing in the pipe. The sensor 1 is moreover inserted into said tube in such a way that the first surface of the deformation element 111 faces the lumen 3 of the tube, so that the sensor lug projects into said lumen. In the exemplary embodiment shown here, there is at both the inlet end 3+ and the outlet end 3 # a flange, which is used in each case to produce a leak-free flange connection to a respective corresponding flange on an inlet-side or outlet-side line segment of the pipe. Furthermore, as shown in FIG. 1 or 2, the tube 3 can be substantially straight, namely, for example, in the form of a hollow cylinder with a circular cross section in such a way that the tube 3 has an imaginary straight longitudinal axis L connecting the inlet end 3+ and the outlet end 3 #. In the exemplary embodiment shown in FIGS. 1 and 2, respectively, the sensor 1 is inserted into the lumen of the tube from the outside through an opening 3 formed in the wall and is fixed, for example also releasably, from the outside to the wall 3* in the region of said opening in such a way that the surface 111+ of the deformation element 111 faces the lumen 3 of the tube 3 and therefore the sensor lug 112 protrudes into said lumen. Especially, the sensor 1 is inserted into the opening 3 in such a way that the deformation element 111 covers or hermetically seals the opening 3. Said opening can be designed, for example, in such a way that it has, as is quite usual in measurement systems of the type in question, an (inner) diameter in a range between 10 mm and approximately 50 mm. According to a further embodiment of the invention, a socket 3a used to hold the deformation element 111 or the sensor 1 formed therewith on the wall 3* is formed in the opening 3. In this case, the sensor 1 can, for example, be fixed to the tube 3 by integral bonding, especially by welding or soldering, of the deformation element 111 and wall 3*; however, it can for example also be detachably connected to the tube 3, namely, for example, screwed thereto or screwed thereon. Furthermore, at least one sealing face, for example also a circumferential or circular-ring-shaped sealing face, can be formed in the socket 3a and is configured to seal the opening 3 correspondingly in cooperation with the deformation element 111 and an optionally provided, for example annular or annular disk-shaped, sealing element. According to a further embodiment of the invention, the sensor 1 and the tube 3 are further dimensioned such that a length of the sensor lug 112, measured as the minimum distance between a proximal end of the sensor lug 112, namely the end bordering the deformation element 111 and the distal end of the sensor lug 112, corresponds to more than half of a caliber DN of the tube 3 and less than 95% of said caliber DN. For example, the length of the sensor lug 112 can also be selected, as is quite usual with a comparatively small caliber of less than 50 mm, in such a way that said distal end of the sensor lug 112 has only a very small minimum distance from the wall 3* of the tube 3. In the case of tubes with a comparatively large caliber of 50 mm or more, the sensor lug 112 can also, as is quite usual in the case of measurement systems of the type in question or as can also be seen from FIG. 2, be significantly shorter than half of a caliber of the tube 3, for example.

[0063] In the exemplary embodiment shown in FIGS. 1 and 2, respectively, the measurement system is specifically designed as a vortex flow meter with a resistance element 4 arranged in the lumen of the tube 3here, namely, upstream of sensor 1, namely in the (main) direction of flow upstream of the sensorand serving to bring about a K?rm?n vortex street in the flowing fluid. Here, the sensor and the resistance element are, especially, dimensioned and arranged such that the sensor lug 112 projects into the lumen 3* of the tube, or into the fluid conducted, in such a region which during operation of the measurement system is regularly taken up a (stationarily formed) Kerman vortex street, so that the pressure fluctuations detected by means of the sensor are periodic pressure fluctuations caused by vortices shed at the resistance element 4 at a separation rate (?1/f.sub.Vtx), and the sensor signal s1 has a signal frequency (?f.sub.Vtx) corresponding to the separation rate of said vortices. In the exemplary embodiment shown here, the vortex flow meter is moreover designed as a compact-type measurement system in which the measurement electronics 2 are accommodated in a protective housing 20 held on the tube, for example by means of a neck-like connection piece 30.

[0064] According to a further embodiment of the invention, in order to compensate for forces and/or moments resulting from random movements of the sensor, for example as a result of vibration of the aforementioned pipe connected to the tube, or to avoid undesired movements of the sensor lug or of the deformation element 111 resulting therefrom, namely distorting the sensor signal s1, the sensor 1 further has a compensating element 114, for example a rod-shaped, planar or sleeve-shaped compensating element, extending from the second surface 111 # of the deformation element 111. The compensating element 114 can, for example, consist of the same material as the deformation element and/or the sensor lug, for example a metal. For example, the compensating element 114 can be produced from stainless steel or a nickel-based alloy. According to a further embodiment of the invention, the deformation element 111 and the compensating element 114 are integrally bonded to one another, for example welded or soldered to one another, and therefore the compensating element 114 and the deformation element 111 are produced from materials that can be integrally bonded to one another accordingly. Alternatively, however, the deformation element 111 and the compensating element 114 can also be components of one and the same monolithic molded part, for example also in such a way that the sensor lug 111, the deformation element 112 and the compensating element 114 are components of said molded part. The sensor lug 112 and the compensating element 114 can also be arranged in alignment with one another, as can also be seen by viewing FIGS. 3c and 3d together, in such a way that a main axis of inertia of the sensor lug 112 coincides in extension with a main axis of inertia of the compensating element 114. Alternatively or in addition, the compensating element 114 and the deformation element 111 can also be positioned and aligned with one another such that a main axis of inertia of the deformation element 111 coincides in extension with a main axis of inertia of the compensating element 114. According to a further embodiment of the invention, the compensating element and the spring assembly are designed and arranged such that the compensating element extends through the spring assembly, for example in such a way that a main axis of inertia, namely, for example, a longitudinal axis of the compensating element and a main axis of inertia, namely, for example, a longitudinal axis of the spring assembly, run parallel to one another, namely, for example, to be coincident, and/or in such a way that the spring assembly and the compensating element do not contact one another.