Measuring method and measuring system

[0002] The present invention relates to a measuring method and systems for the determination of concentrations or velocities of flows or currents. It more particularly relates to a measuring method and a system to apply the measuring method according to the definition of the claims.

[0003] The determination of concentrations or velocities of flows or currents is of great importance in research and industry. It is e.g. about multiphase flows of solids in gases or liquids, or gas bubbles in liquids, or of liquid droplets in gases or liquids etc. It is also e.g. about moving matter, bulk solids, liquids, surfaces of liquids, webs of paper and fabric etc. The determination of concentrations or velocities of flows or currents reveals a variety of information as e.g. densities, degree of turbulence etc.

[0004] Existing measuring methods as e.g. the dust concentration measurement according to the transmission principle or e.g. the laser Doppler anemometry have disadvantages. These measuring systems are susceptible to soiling and may not be used at high or low temperatures, respectively. Therefore cleanings and dismantlements of the measuring systems are necessary, therefore continuos measurements/process monitoring becomes impossible. Such measuring systems are furthermore expensive and maintenance and application are costly.

[0005] It is the objective of the present invention to provide a measuring method for the determination of concentrations or velocities of flows or currents, which overcomes disadvantages of existing methods. It is a further objective of the invention to provide a measuring system, that eliminates disadvantages of existing systems. The measuring method and its measuring system should be compatible with existing and popular industry standards.

[0006] This objective is achieved by the invention according to the claims.

[0007] The invention serves to determine concentrations or velocities of flows or currents. It concerns flows consisting of different phases as e.g. solids in gases or liquids, or gas bubbles in liquids, or liquid droplets in gases or liquids etc. and it concerns flows as e.g. moving matter, bulk solids, liquids, surfaces of liquids, webs of paper and fabric etc.

[0008] For the determination of concentrations of flows or currents, physical quantities characteristic for concentrations as e.g. backscattered, emitted or transmitted light, radiation or sonic intensities, permeabilities, dielectric constants (permittivities), conductivities, diffractions of micro waves, magnetic or nuclear magnetic resonances (NMR) or temperatures are measured. For the quantitative determination of e.g. solids concentrations calibration parameters are determined by performing e.g. calibration experiments measuring characteristic physical quantities at different known concentrations and hence deriving a mathematical function. Such calibration parameters depend generally on the relevant physical properties of the materials of the flows or currents considered.

[0009] For the determination of velocities of flows or currents, the fluctuations of characteristic physical quantities as e.g. backscattered, emitted or transmitted light, radiation or sonic intensity, permeability, dielectric constant (permittivity), conductivity, diffraction of micro waves, magnetic or nuclear magnetic resonance (NMR) or temperatures, or are measured locally by means of two or three sensor heads and correlated using stochastic methods. The comparison of several of such measured measuring signals allows the correlative determination velocities of e.g. solids, clusters or bubbles. The velocity determination is performed for one or two dimensional flows or currents. The thus used measuring system comprises a measuring probe, in which all optical and electronical components are integrated and protected effectively from environmental influences. It further comprises a power supply for the supply of the measuring probe and a computerized analysis unit for the analysis of the measuring signals measured by the measuring probe. Particularly for the velocity determination, a measuring system with two or three sensor heads placed at different positions is used. The measuring resolution is determined by the distance of the sensor heads from each other. From correlations times of flight between the sensor heads are determined. Flow or current velocities result from quotients of distances of sensor heads and times of flight.

[0010] FIG. 1 schematically shows a part of a measuring system to apply the measuring method, comprising two measuring channels.

[0011] FIG. 2 schematically shows a part of a measuring system to apply the measuring method with three measuring channels.

[0012] FIG. 3 is a perspective view of a part of a first embodiment of a measuring probe of a measuring system according to FIG. 1.

[0013] FIG. 4 is a front view of a part of the first embodiment of the measuring probe according to FIG. 3.

[0014] FIG. 5 is a sectional view along line DD′ of a part of the first embodiment of the measuring probe according to FIG. 4.

[0015] FIG. 6 is a sectional view of a part of a further embodiment of the measuring probe of a measuring system according to FIG. 2.

[0016] FIG. 7 is a front view of a part of the embodiment of the measuring probe of FIG. 6.

[0017] FIG. 8 is a first sectional view along line AA′ of a part of the embodiment of the measuring probe of FIG. 6.

[0018] FIG. 9 is an additional sectional view along line BB′ of a part of the embodiment of the measuring probe of FIG. 6.

[0019] FIG. 10 is an additional sectional view along line CC′ of a part of the embodiment of the measuring probe of FIG. 6.

[0020] FIG. 11 schematically shows a part of an embodiment of an analysis unit of a measuring system.

[0021] FIG. 12 schematically shows an example of the determination of a velocity vector.

[0022] FIG. 13 is a perspective view of a part of a further embodiment of a measuring probe of a measuring system with one measuring channel.

[0023] FIG. 14 is a sectional view of a part of an embodiment of a measuring probe of a measuring system with standardization unit.

[0024] FIG. 15 is a sectional view of a part of an embodiment of a measuring probe of a measuring system with homogenization device.

[0025] FIG. 16aschematically shows a part of the measuring probe with one sensor head and light conductor means conducting the backscattered light to a sensor.

[0026] FIG. 16bshows the scheme of FIG. 16a, further comprising light guiding means for guiding a fraction of the emitted light to an additional sensor.

[0027] FIG. 17 is a flow chart showing one embodiment of a process for calculating flow velocity.

[0028] FIG. 18ais a flow chart showing an embodiment of a process for determining physical properties of flows or currents using at least one sensor head.

[0029] FIG. 18bis a flow chart further showing an embodiment of a calibration process used to determine calibration parameters used in the process of FIG. 18a.

[0030] The present measuring method for the determination of concentrations or velocities of flows or currents is based on the measurement of amplitudes or fluctuations of characteristic physical parameters as e.g. backscattered, emitted or transmitted light, radiation or sonic intensities, permeabilities, dielectric constants (permittivities), conductivities, diffractions of micro waves, magnetic or nuclear magnetic resonances (NMR) or temperatures. The measuring method is applicable for the measurement for all kind of amplitudes or fluctuations. In order to provide a concise description, in the following the invention is explained in detail using the example of light backscattering of flows or currents only. Knowing the present invention, an expert may apply the measuring method for the measurement for other, not in detail explained amplitudes or fluctuations of characteristic physical parameters of flows or currents.

[0031] Now referring to the figures, for the concentration determination of flows or currents as a parameter e.g. the backscattered light intensity may be measured. For a quantitative determination of e.g. solids concentrations calibration parameters are determined by using a calibration curve, which depends for the exemplary parameter backscattered light on optical properties as color, surface of the solids and their particle size. Advantageous a measuring system with at least one sensor head 1 (cf. FIG. 13) is used or a measuring system with at least two sensor heads positioned displaced to each other 1, 1′, 1″ (cf. FIG. 1, 2) is used. With the measuring system parameters are measured and the measured parameters are converted into measuring signals. These measuring signals are plotted as a function of the concentration and related to each other by a mathematical function using calibration parameters.

[0032] For the velocity determination of flows or currents, the fluctuations of the backscattered light intensity are measured and correlated using stochastic methods. The comparison of several of such measured measuring signals allows the correlative determination of velocities of e.g. solids, clusters or bubbles. For the velocity determination of a one dimensional flow, e.g. in a tube, preferably a measuring system with two sensor heads positioned displaced to each other 1, 1′ (cf. FIG. 1) is used. For the velocity determination of a two dimensional flow in a plane preferably a measuring system with three sensor heads placed at different positions 1, 1′, 1″ (cf. FIG. 2) is used. It is presumed that macroscopic homogenous flows or currents are present, that are similar in the measuring volume in front of the different sensor heads. Further, for a correct measurement, all sensor heads have to be positioned in a way, that they detect backscattered light from the flows or currents. This is illustrated in FIGS. 1 and 2 by parallel flow arrows of essentially equal length. The two or three sensor heads emit light, the light forming two or three light rays. The measuring resolution is defined by the optical distance between the sensor heads Δd_opt. Preferably, the sensor heads are aligned in a measuring plane perpendicular to the flows or currents. In the example, where light backscattering is used as a parameter, the distance between the sensor heads is defined to be the optical distance between the sensor heads, i.e. the mutual distance of the rays emitted by the sensor heads at the spot of the backscattering in the measuring plane. The effective optical distance eff. Δd_optis the projection of the optical distance between the sensor heads Δd_optparallel to the flow into the measuring plane perpendicular to the flows or currents.

[0033] Typical optical distances between sensor heads are a few millimeters. Typical velocities, that may be measured by the measuring system, are between 0.05 and 200 m/s. Concentrations may be measured by the measuring system with sampling rates of 1 to 100 kHz. Velocities may be measured by the measuring system with measuring frequencies of 10 to 5,000 Hz. These values are only examples and depend on the hardware used (measuring probe, computerized analysis unit, measuring lines, etc.). They therefore do not constrict the application range of the invention.

[0034] FIGS. 3 to 10 and 13 show parts of exemplary embodiments of sensor heads 1, 1′, 1″ of the measuring system. The light is detected by a specially designed optics, which defines a measuring volume that depends on the application, and guided by light conductor means 2 into a measuring probe 10. The intensity of the light backscattered by the flows or currents is guided by light conductor means 2 to sensors of the measuring probe where it is detected. An according scheme is shown in FIG. 16a, where also the light source, i.e. a laser is displayed. In fact, all kinds of light sources such as lasers, cold light lamps, etc. may be used in the present measuring method to determine concentrations or velocities. Known lasers are e.g. laser diodes, known light conductor means are e.g. optical fibers, known sensors are e.g. photo diodes. These sensors yield measuring signals, which are guided by measuring lines 3, 3′, 3″ to an analysis unit. The measuring signals of the two or three sensor heads are preferably guided by two or three measuring lines, i.e. each sensor head has a measuring line by itself.

[0035] Such a photometric detection of the backscattered light intensities may be very sensitive, so that even at very uniform flows the measuring signals fluctuate stochastically. These fluctuations are analyzed for the velocity determination by correlating the measuring signals of the two or three sensor heads. Using these correlations, the times of flight are determined corresponding to the sensor heads. The time of flight τ is defined as the time corresponding to a favored correlation coefficient. The numerical calculation of the correlation uses known mathematical methods, e.g. as cross correlation using the Wiener-Khinchin-theorem or as Moebius-correlation, both known to experts in this field and not explained in more details here. In the case of the cross correlation, the favored correlation coefficient is the maximum correlation coefficient. To carry out the correlation, knowing the present invention, an expert has a large variety of possibilities.

[0036] In the case of the 1-dimensional velocity determination using two sensor heads, the absolute value of the velocity V in direction of the connection of the two sensor heads results directly from the quotient of the effective optical distance between the sensor heads eff. Δd_optand the time of flight τ: $V=\frac{\mathrm{eff}.\Delta d_{\mathrm{opt}.}}{\tau }$

[0037] In the case of the 2-dimensional velocity determination using three sensor heads, three times of flight τ are determined in analogy to the 1-dimensional case. For this purpose, three effective optical distances between the sensor heads eff. Δd_optare used. By determining the quotient of these three effective optical distances between sensor heads eff. Δd_optand the corresponding times of flight τ three absolute velocity values v_a, v_b, v_care calculated. These absolute velocity values are associated to the measuring signals of two sensor heads. As an example, the absolute velocity value v_ais associated to the measuring signals of the two sensor heads 1 and 1′, the absolute velocity value v_bis associated to the measuring signals of the two sensor heads 1′ and 1″ and the absolute velocity value v_cis associated to the measuring signals of the two sensor heads 1″ and 1. Out of these three absolute velocity values, two are necessary for the determination of an independent velocity vector. This velocity vector is related to one sensor head, to which two absolute velocity values are associated. E.g., the velocity vector, to which two absolute velocity values v_aand v_bare associated, is related to the first sensor head 1′. This determination of the velocity vector is preferably achieved by consideration of the vectors involved. This is illustrated in FIG. 12. The absolute value of a first absolute velocity value v_ais drawn in direction of the connection of the first sensor head 1′ to the first associated sensor head 1, the absolute value of a second absolute velocity value v_bis drawn in direction of the connection of the first sensor head 1′ to the second associated sensor head 1″. A connecting vector c=v_b−v_ais defined. The velocity vector v is the distance vector between the first sensor head 1′ and the connecting line between the endings of the such drawn absolute velocity values v_aund v_b: $v=v_a+\frac{-v_a·c}{c^2}c=v_a+\frac{-v_a·\left(v_b-v_a\right)}{{\left(v_b-v_a\right)}^2}\left(v_b-v_a\right)$

[0038] By cyclic permutation of the three absolute velocity values, such a velocity vector can be determined for each sensor head. The vectors of a thus resulting velocity vector triples have to coincide within a measuring tolerance to be defined freely. This allows for a simple and quick check of the measuring method by comparing the three velocity vectors using a variation coefficient. Velocity vector triples that do not correspond to the defined measuring tolerance are rejected, since the initially postulated assumptions regarding homogeneity of the flows or currents etc. are obviously not fulfilled.

[0039] Preferably, this analysis of the measuring signals is done in the analysis unit using measuring windows to be chosen freely. FIG. 11 shows a part of an embodiment of such an analysis unit 20 with shifted measuring windows 21, 21′, 21″. Measuring signals are fed by measuring lines 3, 3′, 3″. Each of these measuring windows comprises a defined number of measuring signals. As analysis units, commercially available computers with data acquisition interfaces may be used.

[0040] The present method allows the simultaneous measurement of concentrations and velocities in particular, be it off-line, on-line or in-line. Particularly, the present method allows a permanent in-line process monitoring. E.g. solids concentrations in the range of 1 g/m³-1,500 kg/m³may be determined in-line.

[0041] The present method allows to standardize the detected physical parameters. A standardizing is optional and allows e.g. the determination of calibration data independently of a specific measuring instrument or in-situ checks of the stability of the measuring instruments. Such in-situ checks may be carried out in periodic or non periodic time intervals. Standardizing of the measured parameters is illustrated in FIG. 14 by an embodiment of a standardizing device 6. This is a standardizing device for e.g. concentration measurements of flows or currents using backscattered light intensities. In this embodiment, the standardizing device is a standardizing reflector in the form of a cap. This standardizing reflector is mounted onto at least one sensor head 1 with light conductor means 2 in a light transparent way. To avoid influences from extrinsic light the standardizing reflector itself is light impermeable and contains two or more for light semi-transparent reflector elements 60, 60′, 60″ positioned in the optical path of the emitted and reflected light. The reflector elements have e.g. a disk like shape and are fabricated of light semi-permeable material such as glass, plastic, metal, etc. By the thus repeated combination of reflection and transmission e.g. a 2-phase-flow or current is simulated. The total of the reflected light is detected as a parameter by at least one sensor head. The therefrom determined measuring signal is used as standardizing signal for the standardizing. Knowing the present invention, an expert has various possibilities for the realization of standardizing devices to use with the measuring system.

[0042] In measurements of concentrations or velocities of flows or currents, the present invention in addition allows the determination of representative mean values. Such representative mean values are e.g. necessary for mass flow rate measurements. Such a determination of representative mean values, as demonstrated using an homogenization device 7 in the embodiment of FIG. 15., is optional. A homogenization device works e.g. using the physical parameter light intensity. It may e.g. be mounted in a transport duct for flows or currents upstream of at least one sensor head 1. The homogenization device features a convergent inlet 70 for the acceleration of the flow or current. Further, it features an homogenization part 71 for the homogenization of the concentration and velocity distribution of the flow or current. In the homogenization part e.g. solid strands of flow or current are dispersed by acceleration and/or elevated turbulence. The measuring volume is confined by the flow or current or it depends on the measuring principle and is not influenced by the homogenization device. Downstream of the homogenization device, a divergent exit 72 is positioned. This exit 72 may be e.g. a slim diffusor and allows to recover most of the pressure drop caused accelerating the flow or current at the inlet. The homogenization device may be adapted to different tube diameters. It may be operated with different measuring systems and has different possible measuring positions 73 for the installation of at least one sensor head. The confined or limited measuring volume of a sensor head mounted at the homogenization device covers a greater or the whole part of the tube diameter. Therefore, a greater part of flow or current, rendered more representative by means of an homogenization device, is measured, leading to an higher measuring accuracy.

[0043] Soilings by the flow or current medium may lead to measuring errors and measuring failures. To prevent such soilings of the sensor heads by the flow or current medium a cleaning unit is foreseen. This cleaning unit is optional, the measuring method is applicable without it. Particularly the cleaning unit is used for flow or current media, which tend to stick onto the sensor head easily and may cover them. In an embodiment, the cleaning unit consists of cleaning fluid flow between the sensor heads and the flow or current, in such a way that the flow or current can not reach the sensor heads. As cleaning fluid known industrial liquids and gases as water, air, inert gases, nitrogen, etc. may be used. Preferably, the cleaning fluid flows via inlet and exit lines 4, 4′ and redirections 5 to a flat cleaning volume 5′ between the sensor heads and the flow medium and thus prevents the flow or current medium from settling onto the sensor heads. Such a flat cleaning volume has e.g. a thickness of just a few millimeters forming a cleaning fluid film of just a few millimeters thickness. The inlet and exit lines and the redirections are designed and arranged in a way, that the cleaning fluid flow itself does not affect/disturb/falsify the concentration and velocity measurement. Preferably, the cleaning fluid flow is redirected by a redirection such that the cleaning fluid flow is mainly momentum free in direction of the axis of the sensor heads. Designing such a cleaning unit an expert has various design possibilities. As an example, in the embodiment of FIG. 5 redirections 5 are provided near the sensor heads 1 and optional check valves 8 are provided in the inlet lines 4.

[0044] The stable and reproducible detection of small light intensities is difficult and requires the exclusion of mechanical (fibers!), electronic and temperature influences. If such influences could not be excluded, they have to be compensated for, e.g. temperature. Furthermore the light source used namely the laser has to be stable for longer time periods. To improve the accuracy and stability the alternative embodiment described with respect to FIG. 16bis proposed: In contrast to the embodiment shown in FIG. 16a, by means of a light decoupling device, a small fraction of the light guided by light conductor means 2 to the sensor head 1 is decoupled and guided to a photosensing device, which detects rather than one absolute light intensity now the quotient of the backscattered and the decoupled light intensity. Such a setup is less dependent on influences such as temperatures and thus allows higher accuracies and a higher long term stability.