BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram of a dwelling with the HVAC system.
FIG. 2 is the graphs of pressures at air filter sides as function of its clogging.
FIG. 3 is a graph showing dependence of the air flow rate as a function of the air filter clogging.
FIG. 4 show an air ducts with a bypass tube with the air flow sensor.
FIG. 5 shows a sensing tube with multiple openings facing downstream.
FIG. 6 shows a sensing tube with an opening normal to the flow direction.
FIG. 7 shows a flow/pressure sensor with the sensing tube inside the air duct.
FIG. 8 represents a thermo-anemometer sensor with a thermistor.
FIG. 9 is a thermo-anemometer sensor with a thermo-couple
FIG. 10 depicts a thermo-anemometer sensor fabricated with the MEMS technology.
FIG. 11 is circuit diagram of a servo loop for the air flow sensor with thermistor sensors.
FIG. 12 shows a graph of the servo circuit output voltage as function of mass flow rate.
FIG. 13 shows a pressure differential detector for a security system.
FIG. 14 illustrates a security sensor installed into a wall between two adjacent rooms.
FIG. 15 shows is circuit diagram of a servo loop for the air flow sensor with thermo-couples.
FIG. 16 is an illustration of a flow-sensor assembled on a circuit board.
FIG. 17 depicts an air flow rate near the sensor in a security system.
FIG. 18 shows a flow probe arrangement for an internal combustion engine.
DESCRIPTION OF PREFERRED EMBODIMENTS
As it follows from Eq. (1), a differential air pressure can be computed from the air flow rate from the following formula:
and therefore, a differential pressure measurement may be substituted by measurement of the air flow as shown in a general diagram of FIG. 4. The air duct 26 contains an air flow restriction 27 that can be caused, for example, by an air duct geometry, the air filter, or other components. The air flow 22 is produced by the air blower 5. A bypass tube 28 circumvents the flow restriction 27, thus diverting a small portion of air flow 29 to go through the bypass tube 28 and exit as flow 30 at the other side of restriction 27. The respective ends of the bypass tube 28 are exposed to two air pressures, P1 and P2. An air flow monitor 10 is installed at the bypass tube 28 with its flow sensor 11 being exposed to the interior of the bypass tube 28. Since the airflow 30 inside the bypass tube 28 related to a differential pressure P1-2=P1−P2, this pressure can be computed with the use of Eq. (2).
While FIG. 4 illustrates a general operating principle of the present invention, the practical implementations can take various forms. A preferred embodiment of the monitor 10 with a flow sensor is depicted in FIG. 7. The air duct 4 conducts air flow 22. At a particular spot of its inner cross-section, a static air pressure P1 exists (with respect to the external pressure). The sensing tube 15 is inserted into the air duct 4 to be positioned near a spot of the interest (the one with pressure P1). The tube has an opening 36 facing downstream from the flow 22. At the other side of the sensing tube 15, there is an inlet tube 31 with the opening 16 exposed to external pressure P2 that may be the atmospheric pressure. In-between the sensing tube 15 and the inlet tube 31, there are two sensors: the reference temperature sensor 18 supported by wires 25 and the TA sensor 17 that is supported by wires 23 and 24 (TA stands for “thermo-anemometer”). Both sensors are mounted on a printed circuit board 19 that has an opening 68 to allow air flow 20 to pass by the sensors 17 and 18. Note that this arrangement responds to an absolute pressure differential and absolute value of air flow (regardless of the direction of the air flow 22). This means that the air flow 20 may go in either direction inside the interior 14 of the sensing tube 15, depending whether P1-2 is positive or negative. It is important that sensors 17 and 18 are thermally decoupled from one another. The sensing tube 15 may have various types of openings. If the opening faces downstream, the measured pressure will be static. If it faces upstream, the measured pressure will be static plus dynamic. FIG. 5 shows the multiple openings 33a, 33b, etc. which allow exposing the tube's 15a interior to different points of the air flow 22 and thus to different static air pressures. The integral air flow through the sensing tube 15a will be the function of all these pressures. Another practical type of an opening is depicted in FIG. 6, where at least one opening 35 is made at the end of the sensing tube 15b. This opening(s) 35 is normal to the air flow 22 and thus is exposed to the static pressure. Note that optionally an additional side opening 33 may be combined with the end opening(s) 35.
FIG. 8 depicts the TA sensor 17 built on a substrate 40 which can be a ceramic, plastic or metal. If metal, the substrate 40 should have electrically isolated front surface 37. On the front surface 37, a resistive layer (heater 42) is deposited. It has a typical resistance between 10 and 100 Ohms. The heater 42 is connected to terminals 55 and 56. The heater 42 temperature can be elevated by passing electric current through terminals 55 and 56. A temperature sensor 41 is attached and thermally coupled to the heater 42 so that temperature of the heater may be measured. As the temperature sensor 41, various types of temperature sensors can be employed. One example is an NTC thermistor with the top-bottom electrodes 59 and 60 attached to the conductors 53 and 54. Since the TA sensor 17 is exposed to the air flow, for a better protection from the airborne contaminants, it may be enveloped by a protective coating (not shown), such as glass, epoxy, etc. Thermal conductivity of such a layer should be as high as practical. FIG. 9 illustrates another design of a temperature sensor with a thermo-couple joint 113 of two dissimilar wires 111 and 112.
A reference sensor 18 is a small conventional temperature sensor fabricated, for example, in a bead shape and is not depicted here. It shall be positioned in the same air flow as the TA sensor 17 but must be thermally decoupled from the TA sensor 17. The location of both sensors in the air flow 20 is illustrated in FIG. 7.
An air flow detector design which is a combination of a reference sensor 18 and the TA sensor 17 fabricated with the MEMS technology is shown in FIG. 10. The combined sensor is fabricated as a silicon frame 61 with opening 63 where air flow can pass though. All electrical parts are formed and deposited on the front surface 62. A thin membrane 64 is etched in the center of the opening 63 and is supported by the silicon links 65. A thickness of the membrane 64 may me on the range of 1 micrometer. A resistive heater 42 is formed on the membrane 64 while the temperature sensor 41 is also located on the same membrane 64. The heater 42 and temperature sensor 41 may be either on top of one another or inter-digitized side by side. It is important that they are thermally coupled. The reference temperature sensor 18 is positioned on the frame 61 and exposed to the same air flow. The sensor 18 is connected to the terminal pads 57 and 58. The temperature sensors 18 and 41 can be resistive, semiconductive or thermoelectric. The resistive heater 42 is connected to terminals 55 and 56 while the second temperature sensor 41 is connected to conductors 53 and 54 via the conductive paths 66. The combined sensor of FIG. 9 can be positioned at the opening 68 (FIG. 7) in place of the discrete sensors 17 and 18. An alternative design of the MEMS sensor is without the opening 63 where the air flow hoe parallel to membrane 64 which is directly supported by the frame 61.
FIG. 11 shows a servo circuit diagram where the temperature sensors are the NTC thermistors. The TA sensor 17 consists of thermally coupled thermistor temperature sensor 41 and heater 42. Along with the reference temperature sensor 18 they are exposed to air flow 22 passing through the sensing tube 15. A thermal insulator 100 is positioned between the sensors 17 and 18. A thermal insulator may be an air gap between the sensors as illustrated in FIGS. 7 and 10. The reference temperature sensor 18 measures the air temperature while the TA sensor measures the heat loss resulted from the air flow. These two sensors 18 and 17 along with two resistors 43 and 44 form a Wheatstone bridge circuit having the outputs 48 and 49 connected to the servo amplifier 46. Two additional resistors 51 and 52 can be connected to the reference temperature sensor 18 for improving its operation over a broader range of the air temperatures. The ratio of the resistors 43 and 44 is such as to correspond to the second temperature sensor 41 be warmer than the reference temperature sensor 18 by a constant thermal gradient of several degree C., typically, 4-7° C.
where Ra is the combined resistance of the reference temperature sensor 18 at the air temperature Ta, and the resistors 52 and 51, Rg is the resistance of the temperature sensor (inside the TA sensor 17) when its temperature Tg=Ta+g, R43 and R44 are the resistances of the resistors 43 and 44 respectively, and g is the constant temperature gradient. The output of the servo amplifier 46 drives the current amplifier 47 that is capable of pushing a sufficient electric current through the heater 42. The purpose of the servo circuit is to balance the Whetstone bridge by elevating temperature of the heater 42 and, subsequently, of the second temperature sensor 41. When air flow 22 cools down the TA sensor 17, more current is required through heater 42 to maintain the constant temperature gradient above ambient temperature that is measured by the reference temperature sensor 18. The servo amplifier 46 may be substituted with a micro-controller having a software that provides a PID function to control the heater 42. The voltage 50 across the heater 42 is the output of the measurement circuit that represents the magnitude of the mass flow rate through the test tube 15. FIG. 11 illustrates dependence of the output voltage 50 from the air mass flow rate. Note that at zero flow rate, the output has a bias of V0.
Another embodiment of the flow sensor can use thermo-couples as temperature sensors. This is illustrated by the servo-circuit of FIG. 15 where a “hot” thermo-couple 113 is connected in series with a “cold” thermocouple 114 and, in turn, to a pre-amplifier 115. A reference signal 117 is applied to the servo amplifier 46. The rest of the circuit operates similarly to the circuit of FIG. 11. The “cold” thermocouple 114 measures the air temperature. Note that an additional heating element 115 may be added. It's function is to compensate for the conductive heat losses from heater 113 via the supporting structure. This idea is further illustrated in FIG. 16 which shows an air flow sensor fabricated on a miniature circuit board 118. The board may also carry an electronic circuit 119. Note that different parts of the circuit board 118 has cut-outs 120-124 to reduce a conductive heat flow from the sensing heater 42 toward the reference (“cold”) thermocouple junction 125. The thermocouple wires 127 and 128 pass under the additional heating element 115 before forming a “cold” junction 114. The heating element conductors are not shown in FIG. 16.
Security System Applications
To illustrate how the present invention can be employed in a security system, consider FIG. 13. The purpose of the security device is to respond to relatively rapid changes in the air pressure inside a building. Normally, air pressure in a protected facility changes relatively slowly, along with the external atmospheric pressure. When a door or window is being closed or opened, the air pressure may vary. This can be detected by the device of FIG. 13. The arrangement is similar to one shown in FIG. 7 with the following differences. A short tube 90 (between 0.5 and 5″ long) is exposed to the room pressure P1. The reference sensor 18 and TA sensor 17 are positioned at the other end of the tube 90 at the opening 68 of the board 19 and supported by wires 25 and 69. The other side of the board 19 is covered by enclosure 74 which has the internal pressure P2. When pressure P1 changes, air flow 22 goes through the tube 90, the opening 68 to the enclosure 72. At least one hole 72 in the enclosure helps to facilitate the air movement. The servo circuit 71 is connected to the board 19 and generates the output signal 101 that is fed into the processor 73. The variable pressure differential is shown in FIG. 17. The servo circuit output signal has a shape similar the pressure signal of FIG. 17. The processor 73 analyzes rates of the differential pressure changes and identifies if the rate of change is higher than a pre-set threshold value. It is seeing that the rate Δb is greater than Δa. When the rate of change is sufficiently high, the alarm 70 is initiated.
FIG. 14 shows how the similar principle can be employed for two adjacent rooms in a building. The rooms A and B are separated by a wall 75 and have different air pressures P1 and P2, respectively. The sensors 17 and 18 are positioned between two receptive tubes 76 and 78 that respectively face the rooms A and B. The variable air flow 22 is resulted from the variations in pressures in one or both rooms and can be processed in the circuits similar to FIGS. 11 and 15.
Burners and Internal Combustion Engine Applications
A sensor based on the present invention as described above has a natural application for the fuel burners and automotive machinery where the internal combustion engines are in use. FIG. 18 illustrates parts of a gasoline engine with the air filter assembly 84. Air inlet 82 is positioned upstream from the air filter 84 and carries air flow sensing tube 15. The tube 15 is connected through a flexible tubing 83 to the air flow monitor 10. The monitor contain an air flow sensor that is built in accordance to one of the described or implied embodiments of this invention. The monitor 10 is further connected to a signal processor (not shown) that makes use of data received from the air flow monitor 10. One possible use of such monitoring is the detecting of an air filter clogging. The other use is controlling the rate of air intake and control the air-to-fuel mixing ratio to increase the engine or burner efficiency.
Patent Application
20080053196
