Field of invention

The present invention relates to flow sensors in general and in particular to clamp-on ultrasonic flow sensors.

Prior art

Flow measurement is widespread used for measuring flow in industry, buildings and utility grids. Flow can be detected by using various types of flow sensors. The prior art flow sensors include mechanical flow sen sors and ultrasonic flow sensors. Ultrasonic flow sensors are mainly used in two versions, namely delta-time-of-flight for measuring on pure fluids (water, gas, industry liquids, etc.) and Doppler effect for measur ing fluids containing many particles (slurry, liquids with air bubbles, etc.).

All prior art flow sensors, however, have a predefined non-zero lower flow level representing the lowest flow that can be measured by using the flow sensor. Below the lower flow level, no flow can be detected. This is a major drawback. Accordingly, it would be desirable to be able to provide a solution to this problem.

Since the prior art flow sensors fail to detect lower flow rates (aka speed or volume), relative low flow rates are often difficult or impossible to detect. At the same time, the prior art delta-time-of-flight flow sensors are designed for detecting flow in a homogeneous medium, leading to measurement error if the medium is inhomogeneous. It will therefore lead to e.g. :

A. Measurement error.

B. Limitations against detecting small leakages and similar, which can be damaging to e.g. the building or production where the sensor is installed.

C. Difficulties in detection no-flow (the fluid stands still in the pipe), which is needed to identify the off-set of the sensor. Thus, there is a need for a method and a flow sensor which reduces or even eliminates the above-mentioned disadvantages of the prior art.

Summary of the invention

The object of the present invention can be achieved by a flow sensor as defined in claim 1 and by a method as defined in claim 15. Preferred embodiments are defined in the dependent subclaims, explained in the following description and illustrated in the accompanying drawings.

The flow sensor according to the invention is a flow sensor configured to measure the flow of a fluid flowing through a tubular structure, wherein the flow sensor comprises a first detection unit that is configured to de tect flows above a predefined lower flow level representing the lowest flow that can be measured by using the first detection unit, wherein the flow sensor comprises a second detection unit that comprises: a first temperature sensor arranged and configured to detect the temperature of the surroundings (the ambient temperature); a second temperature sensor arranged and configured to detect the temperature of the fluid; a data processor connected to the temperature sensors, wherein the second detection unit is configured to estimate the flow be low the lower flow level on the basis of the temperature difference be tween the surroundings and a fluid, wherein the temperature difference between is measured by the first temperature sensor and the second temperature sensor, wherein the second detection unit is configured to estimate the flow below the lower flow level on the basis of one or more measurements made in a flow-calibration-area, in which-flow- calibration-area the flow sensor can detect the flow that depends on the temperature difference, wherein the one or more measurements made in the flow-calibration-area are used to determine one or more parame ters required to determine how the flow depends on the temperature difference in the flow area below the flow-calibration-area.

Hereby, it is possible to provide a sensor that can detect flows in a larg er flow range than the prior art flow sensors. The flow sensor according to the invention can in particular detect flows below the lower flow level.

The flow sensor according to the invention is a flow sensor configured to measure the flow of a fluid. In one embodiment, the fluid is a liquid. In one embodiment, the fluid is a water-containing liquid. In one embodi ment, the fluid is a gas.

The fluid is flowing through a tubular structure. In one embodiment, the tubular structure is a pipe. In one embodiment, the tubular structure is a hose. In one embodiment, the tubular structure is a container. In one embodiment, the tubular structure is a box.

The flow sensor comprises a first detection unit that is configured to de tect flows above a predefined lower flow level representing the lowest flow that can be measured by using the first detection unit. The first detection unit may a structure of a positive displacement meter that requires fluid to mechanically displace components of the mechanical flow detection unit in order to provide flow measurements. In one em bodiment, the first detection unit is a turbine. In one embodiment, the first detection unit is an impeller.

The first detection unit may a structure of an ultrasonic flow sensor. In one embodiment, the first detection unit comprises one or more ultra sonic transducers.

In one embodiment, the first detection unit comprises one or more ul trasonic transmitters and one or more ultrasonic receivers.

The flow sensor comprises a second detection unit that comprises: a first temperature sensor arranged and configured to detect the temperature of the surroundings (the ambient temperature); a second temperature sensor arranged and configured to detect the temperature of the fluid; a data processor connected to the temperature sensors. The data processor may be a micro-processor.

The second detection unit is configured to estimate the flow below the lower flow level on the basis of the temperature difference between the surroundings and a fluid, wherein the temperature difference between is measured by the first temperature sensor and the second temperature sensor.

In one embodiment, the second detection unit is configured to estimate the flow below the lower flow level on the basis of a single measurement made in a flow-calibration-area. In some situations a single measure ment may be sufficient to determine the one or more parameters re quired to determine how the flow depends on the temperature differ ence in the flow area below the flow-calibration-area.

In one embodiment, the second detection unit is configured to estimate the flow below the lower flow level on the basis of two or more meas urements made in a flow-calibration-area.

In one embodiment, the second detection unit contains a storage con taining information about how the flow depends on the temperature dif ference, wherein the data processor is configured to access and use said information in such a manner that the data processor can determine the flow on the basis of the temperature difference. In the flow range below the lower flow level, the second detection unit can detect the flow on the basis of the temperature difference value. This can be accomplished, when the relationship between the flow and the temperature difference is known and stored in the storage.

The second detection unit is configured to estimate the flow below the lower flow level on the basis of one or more measurements made in a flow-calibration-area, in which flow-calibration-area the flow sensor can detect the flow that depends on the temperature difference, wherein the one or more measurements made in the flow-calibration-area are used to determine one or more parameters required to determine how the flow depends on the temperature difference in the flow area below the flow-calibration-area. Accordingly, the flow sensor itself is used to calcu late one or more parameters that allows the flow sensor to estimate low flows (below the lower flow level) on the basis of the detected tempera ture difference.

In an embodiment, the flow sensor is configured to regularly or continu ously: carry out the one or more measurements in a flow-calibration-area and update the more parameters required to determine how the flow depends on the temperature difference in the flow-calibration-area and in the flow area below the flow-calibration-area.

Hereby, it is possible to provide reliable flow measurements and on a regularly basis adjust the parameters according to changes of the ambi ent conditions (e.g. an increased ventilation). The flow sensor is config ured to automatically perform a required number of measurements in the flow-calibration-area and calculate and update the more parameters required to determine how the flow depends on the temperature differ ence in the flow-calibration-area and in the flow area below the flow- calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every second, in which attempts are made to provide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every 5 seconds, in which attempts are made to pro vide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every 10 seconds, in which attempts are made to pro vide one or more measurements in the flow-calibration-area. In one embodiment, the term "regularly or continuously" has to be un derstood as once every 30 seconds, in which attempts are made to pro vide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every minute, in which attempts are made to provide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every 2 minutes, in which attempts are made to pro vide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every 5 minutes, in which attempts are made to pro vide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every 15 minutes, in which attempts are made to pro vide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every 30 minutes, in which attempts are made to pro vide one or more measurements in the flow-calibration-area.

In one embodiment, the term "regularly or continuously" has to be un derstood as once every hour, in which attempts are made to provide one or more measurements in the flow-calibration-area.

When attempts are made to provide one or more measurements in the flow-calibration-area it is: a) in some situations possible to provide useful measurements (this is possible if the flow is within the flow-calibration-area) or b) in some situations not possible to provide useful measurements (this is the case if the flow is not within the flow-calibration-area). In an embodiment, the dependency between the flow (Q) and the temperature difference (AT _Sf ) is defined by of the following equations: where Ci is a constant and DT _B is a temperature difference corresponding to a base flow level. In Fig. 8, the base flow level QB is illustrated.

These equations have two unknowns:

- The temperature difference DT _B corresponding to the base flow level QB and

- The constant Ci.

Accordingly, two measurements made in the flow-calibration-area pro vides sufficient information to determine the dependency between the flow (Q) and the temperature difference (AT _Sf ).

In an embodiment, the second detection unit is integrated in the first detection unit. In an embodiment, the second detection unit and the first detection unit are provided as separated units.

In one embodiment, second detection unit is communicatively connect ed to a storage or an external device containing information about how the flow depends on the temperature difference, wherein the data pro cessor is configured to access and use said information in such a man ner that the data processor can determine the flow on the basis of the temperature difference.

In one embodiment, the second temperature sensor is arranged and configured to detect the temperature of the fluid by measuring a tem perature at the outside of the tubular structure. Hereby it is possible to provide the flow sensor as a clamp-on type flow sensor that can be mounted on the outside of the tubular structure (e.g. a pipe). Accord ingly, there is no need for bringing the second temperature sensor into direct contact with the fluid. In one embodiment, the data processor and the second temperature sensor are arranged inside a housing. Hereby, it is possible to provide a simple, easy mountable and robust flow sensor.

In one embodiment, the first temperature sensor is arranged in the housing. Hereby, all components of the flow sensor can be provided in a single housing.

In one embedment, the first temperature sensor is arranged outside the housing. Hereby, it is possible to take into consideration the heat trans fer caused by convection.

In one embodiment, the second detection unit comprises an intermedi ate temperature sensor arranged and configured to detect an interme diate temperature of a position inside the housing, wherein said position is expected to have a temperature between the ambient temperature and the temperature of the fluid. Hereby, it is possible to provide addi tional information and thus provide an improved estimation of the flow in the low flow range.

In one embodiment, the flow sensor is a clamp-on flow sensor config ured to measure the flow of the fluid from outside the tubular structure. In one embodiment, the flow sensor is an ultrasonic flow sensor and the first detection unit comprises at least one ultrasonic transducer ar ranged to transmit ultrasonic waves and least one ultrasonic transducer arranged to receive ultrasonic waves.

In one embodiment, the data processor is configured to: calculate the expected speed of sound as function of the detected temperature of the fluid) and compare the expected speed of sound as function of the detected temperature of the fluid with a detected value of the speed of sound and calculate a corrected value of the density and the flow if the detect ed value of the speed of sound does not correspond to the expected speed of sound as function of the detected temperature of the fluid.

Hereby, it is possible to improve the flow measurement accuracy in the flow range above the lower flow level.

The expected speed of sound depends on the detected temperature of the fluid) and can be calculated by using a predefined relationship be tween the speed of sound as function of the temperature of the fluid. If the fluid is pure water, by way of example, the relationship between the expected speed of sound as function of the detected temperature of the fluid would be defined as illustrated in Fig. 7.

If the fluid is different from pure water (e.g. water containing salt, sugar or another substance), a different predefined relationship between the expected speed of sound as function of the detected temperature of the fluid can be used.

The expected speed of sound can be compared with a detected value of the speed of sound simply by detecting the speed of sound and making the comparison. The detection can be carried out by using the following formular (16): where c is the sound of speed, L is the distance the sound signal travels and ti and X.2 are the transit time for the sound sig nal transmitted and reflected, respectively.

The corrected value of the density and the flow is calculated if the de tected value of the speed of sound does not correspond to the expected speed of sound. The corrected value of the density can be calculated by using the following equation (18):

, where K is the Bulk Modulus of Elasticity of the fluid and p is the density of the fluid.

In one embodiment, the flow sensor is configured to calculate a correct- ed value of the specific heat capacity of the fluid if the detected value of the speed of sound c does not correspond to the expected speed of sound c as function of the detected temperature of the fluid. Hereby, it is possible to apply the flow sensor to provide a heat energy meter hav ing an improved accuracy. Using a corrected value of the specific heat capacity of the fluid will ensure that the heat energy meter delivers the most accurate measurements.

In one embodiment, the data processor is configured to: calculate the expected speed of sound as function of the detected temperature of the fluid.

In one embodiment, the flow sensor is configured to automatically cal culate the distance L that the transmitted ultrasonic waves and receive ultrasonic waves travel in the fluid on the basis of a detected value of the speed of sound c and the measured time-of-flight. Hereby, it is pos sible to measure the flow in a pipe without knowing the exact dimen sions of the pipe. It is also possible to perform accurate measurements, even if sediments are provided at inside surface of a pipe over time.

The method according to the invention is a method for measuring the flow of a fluid flowing through a tubular structure by using a first detec tion unit that is configured to detect flows above a predefined lower flow level representing the lowest flow that can be measured by using the first detection unit, wherein the method comprises the steps of applying a second detection unit to: detect the temperature of the surroundings (the ambient tempera ture) by means of a first temperature sensor; detect the temperature of the fluid by means of a second tempera ture sensor; estimating the flow below the lower flow level on the basis of the temperature difference between the surroundings and a fluid meas ured by the first temperature sensor and the second temperature sensor, wherein the method comprises the following steps: a) performing one or more flow measurements by means of the first detection unit in a flow-calibration-area, in which flow-calibration-area the flow sensor can detect the flow that flow depends on the tempera ture difference; b) applying the one or more measurements to determine one or more parameters required to determine how the flow depends on the temper ature difference in the flow area below the flow-calibration-area and c) estimating the flow below the lower flow level on the basis of the one or more measurements made in the flow-calibration-area.

Hereby, the method enables flow measurement being carried out in the lower flow ranges.

In one embodiment, the fluid is a liquid. In one embodiment, the fluid is a water-containing liquid. In one embodiment, the fluid is a gas.

In one embodiment, the method comprises the step of estimating the flow below the lower flow level on the basis of a single measurement made in the flow-calibration-area. In some situations a single measure ment may be sufficient to determine the one or more parameters re quired to determine how the flow depends on the temperature differ ence in the flow area below the flow-calibration-area.

In one embodiment, the method comprises the step of estimating the flow below the lower flow level on the basis of two measurements made in the flow-calibration-area.

In one embodiment, the method comprises the step of estimating the flow below the lower flow level on the basis of more than two measure ments made in the flow-calibration-area.

In one embodiment, the method comprises the following steps: storing information about how the flow depends on the temperature difference; using said information to determine the flow on the basis of the temperature difference.

Hereby, the stored information can be used to provide a flow estimation in a simple and reliable manner. The information may be stored in an external device. In one embodiment, the information is stored in a web- based service.

In one embodiment, the method comprises the step of regularly or con- tinuously: carrying out the one or more measurements in a flow-calibration- area and updating the more parameters required to determine how the flow depends on the temperature difference in the flow-calibration-area and in the flow area below the flow-calibration-area.

Hereby, it is possible to provide reliable flow measurements and on a regularly basis adjust the parameters according to changes of the ambi ent conditions (e.g. an increased ventilation). By automatically perform ing a required number of measurements in the flow-calibration-area and calculating and updating the more parameters required to determine how the flow depends on the temperature difference in the flow- calibration-area and in the flow area below the flow-calibration-area, it is possible to provide an improved method.

In one embodiment, the dependency between the flow (Q) and the temperature difference (AT _Sf ) is defined by of the following equations: where Ci is a constant and DT _B is a temperature difference correspond ing to the base flow level.

In one embodiment, the method comprises the following steps: storing in the second detection unit information about how the flow depends on the temperature difference; using said information to determine the flow on the basis of the temperature difference.

Hereby, the stored information can be used to provide a flow estimation in a simple and reliable manner. In one embodiment, the second temperature sensor is arranged and configured to detect the temperature of the fluid by measuring a tem perature at the outside of the tubular structure. Hereby, the need for bringing a temperature sensor in contact with the fluid can be eliminat ed.

In one embodiment, the method is carried out by means of a flow sen sor comprising a data processor, wherein the data processor and the second temperature sensor are arranged inside a housing.

In one embodiment, the method is carried out by using a flow sensor, in which the first temperature sensor is arranged in the housing.

In one embodiment, the method is carried out by using a flow sensor, in which the first temperature sensor is arranged outside the housing.

In one embodiment, the method comprises the step of detecting an in termediate temperature by means of an intermediate temperature sen sor arranged in a position inside a housing that houses the second tem perature sensor and the intermediate temperature sensor, wherein the intermediate temperature is expected to have a value between the am bient temperature and the temperature of the fluid.

In one embodiment, the method comprises the steps of measuring the density and/or the estimated inhomogeneity of the fluid prior to meas uring the flow.

Hereby, it is possible to improve the flow measurements and take into account the density and/or inhomogeneity of the fluid.

In one embodiment, the method comprises the following steps: performing one or more measurements on a sample of the fluid; applying the one or more measurements to calculate the density and/or estimated inhomogeneity of the fluid prior to measuring the flow.

In one embodiment, the estimated inhomogeneity of the fluid corre sponds to the content of one or more substrates in the fluid. The sub strate may one of the following more substances: sugar, salt, ethylene glycol, glycerol or propylene glycol.

In one embodiment, the method is carried out by using a clamp-on flow sensor configured to measure the flow of the fluid from outside the tub ular structure.

In one embodiment, the method is carried out by means of an ultrasonic flow sensor and that the first detection unit comprises at least one ul trasonic transducer arranged to transmit ultrasonic waves and least one ultrasonic transducer arranged to receive ultrasonic waves.

In one embodiment, the method comprises the following steps: calculating the expected speed of sound as function of the detected temperature of the fluid and comparing the expected speed of sound as function of the detected temperature of the fluid with a detected value of the speed of sound and calculating a corrected value of the density and the flow if the de tected value of the speed of sound does not correspond to the ex pected speed of sound as function of the detected temperature of the fluid.

Hereby, it is possible to improve the flow measurement accuracy in the flow range above the lower flow level.

In one embodiment, the method comprises the step of calculating a cor rected value of the specific heat capacity of the fluid if the detected val ue of the speed of sound c does not correspond to the expected speed of sound c as function of the detected temperature of the fluid. Hereby, it is possible to apply the flow sensor to provide a heat energy meter having an improved accuracy. Using a corrected value of the specific heat capacity of the fluid will ensure that the heat energy meter delivers the most accurate measurements. In one embodiment, the method comprises the step of automatically calculating the distance L (that the transmitted ultrasonic waves and receive ultrasonic waves travel in the fluid) on the basis of a detected value of the speed of sound c and the measured time of flight. Hereby, it is possible to measure the flow in a pipe without knowing the exact dimensions of the pipe. It is also possible to perform accurate meas urements, even if sediments are provided at inside surface of a pipe over time.

In one embodiment, the method comprises the step of estimating the heat energy in a heating system or a cooling system. Hereby, it is pos- sible to provide an improved (more accurate) method detect heat ener gy in a heating system or a cooling system.

The heat energy meter according to the invention is a heat energy me ter comprising a sensor according to the invention.

Description of the drawings

The invention will become more fully understood from the detailed de scription given herein below. The accompanying drawings are given by way of illustration only, and thus, they are not limitative of the present invention. In the accompanying drawings:

Fig. 1A shows a graph depicting the temperature difference be tween the surroundings and a fluid flowing through a pipe as function of the fluid flow through the pipe;

Fig. IB shows the low flow portion of the graph shown in Fig. 1A;

Fig. 2A shows a schematic view of a clamp-on type flow sensor ac cording to the invention;

Fig. 2B shows a schematic view of another clamp-on type flow sen sor according to the invention;

Fig. 3A shows a schematic view of a flow sensor according to the invention; Fig. 3B shows a schematic view of another flow sensor according to the invention; Fig. 4A shows a schematic view of a clamp-on type flow sensor ac cording to the invention mounted on the outside of a pipe; Fig. 4B shows a schematic view of another flow sensor according to the invention; Fig. 5A shows a schematic view of a flow sensor according to the invention; Fig. 5B shows a schematic view of another flow sensor according to the invention;

Fig. 6A shows a schematic view of a flow sensor according to the invention; Fig. 6B shows a schematic view of another flow sensor according to the invention; Fig. 7 shows a graph depicting the speed of sound in water as function of the temperature of the water and Fig. 8 shows the flow as function of the temperature difference.

Detailed description of the invention Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, a graph 28 depicting the temperature difference AT _Sf between the surroundings and a fluid flowing through a pipe as function of the fluid flow Q through the pipe is illustrated in Fig. 1A.

It can be seen that the graph 28 (indicated with a solid line) extends above a lower flow level Q _A . The lower flow level Q _A represents the low est flow that can be measured by using prior art flow sensors. Below this lower flow level Q _A , the graph 28, however, has been extrapolated. This lower area 30 is indicated with a dotted ellipse.

Fig. IB illustrates the low flow portion 30 of the graph 28 shown in Fig. 1A. While the prior art flow sensors are not capable of detecting flow below the lower flow level Q _A , the flow sensor and method according to the invention is capable of providing flow measurements below this low- er flow level Q _A .

Above a base flow level Q _B the graph 28 shows that the temperature difference AT _Sf is constant and thus independent of the flow Q.

In the flow-calibration-area B2 between the lower flow level Q _A and the base flow level Q _B the temperature difference AT _Sf increases as function of the flow Q. In this flow-calibration-area B2, a first flow sensor meas urement Mi and a second flow sensor measurement M2 are indicated. It is possible to use one or more of the flow sensor measurements made in the flow-calibration-area B2 to determine the parameters required to determine how the flow Q depends on the temperature difference AT _Sf in the flow-calibration-area B2 and in the flow area Bi below the flow- calibration-area B ₂ .

The temperature difference AT _Sf as function of the flow Q is given by the following equation (1) where DT _B is a temperature difference corresponding to the base flow level Q _B and Ci is a constant.

By performing two measurements Mi and M2, it is possible to determine the two unknown DT _B and Ci from equation (1).

Therefore, it is possible to determine a flow Q _M 3 in the flow area Bi, in which the flow sensor cannot provide any measurements. The flow Q _M 3 can be determined on the basis of a measured temperature difference DT _M 3 detected by the flow sensor. The flow Q _M 3 can be determined by using equation (1) or the following equation (2) defining the flow Q as function of the detected temperature difference AT _Sf :

(2) where Ci is a constant and DT _B is a temperature difference correspond ing to the base flow level Q _B .

The flow sensor and method according to the invention estimates flows Q below the lower flow level Q _A by measuring the temperature differ ence AT _Sf between the surroundings and a fluid flowing through the pipe. The estimation is possible because one or more flow measure ments Mi, M2 made in the flow-calibration-area B2 are used to deter mine the unknown in equation (1) or equation (2). Accordingly, any flow Q in the flow area Bi can be calculated by using equation (2).

In Fig. IB it can be seen that a first flow Qi is detected on the basis of a first measured temperature difference DTi. Likewise, Fig. IB shows that a second flow Q ₂ is detected on the basis of a second measured temper ature difference DT2.

The lower flow level QA corresponds to a measured temperature differ ence DTA. Likewise, the base flow level QB corresponds to a higher measured temperature difference DT _B .

The temperature difference can be detected by using temperature sen sors of the sensor according to the invention. This shown in and ex plained with reference to Fig. 2A, Fig. 2B, Fig. 3A, Fig. 3B and Fig. 4B.

In one example, in the flow-calibration-area B2 , a flow sensor according to the invention used to measure water at 20°C is applied to make a measurement point M2 corresponds to a flow Q _M 2 of 2 ml/s (which is 0.000002 m ³ /s) and a temperature difference DT _M 2 of 10°C. relationship between the temperature difference AT _Sf between the sur roundings and the fluid and the flow Q is given by equation (2): one can calculate the following values: Table 1

In another example, below the lower flow level Q _A , the relationship be tween the temperature difference AT _Sf and the flow Q is given by the equation (2), where c,=4.88 ami _< / = 12.54'^ one can calculate the fol lowing values:

Table 2

Fig. 2A illustrates a schematic view of a clamp-on type flow sensor 1 according to the invention. The flow sensor 1 is arranged to detect the flow of a fluid 26 (e.g. a liquid) in the pipe 2. The flow sensor 1 com prises a data processor 10.

The flow sensor 1 comprises a first temperature sensor 12 arranged to detect the ambient temperature (the temperature in the surrounding of the pipe 2. The flow sensor 1 comprises a second temperature sensor 14 arranged to detect the temperature of the fluid 26. The flow sensor 1 comprises a first ultrasonic wave generator 4 and a second and a sec ond ultrasonic wave generator 4'. The wave generators are formed as piezo transducers 4, 4' arranged and configured to generate ultrasonic waves, which are introduced into the fluid 26 at an angle to the direc tion of flow Q. The flow sensor 1 may be either a Doppler effect type flow sensor 1 or a propagation time measuring type flow sensor 1. It is indicated that both ultrasonic waves 6, 8 travel a distance V2L. Accord ingly, the total distance of travel is L.

The piezo transducers 4, 4' are operated as a transducer to detect the flow Q through a pipe by using acoustic waves 6, 8. In one embodiment, the flow sensor 1 comprises several piezo transducers 4, 4' in order to be less dependent on the profile of the flow Q in the pipe 2. The operat- ing frequency may depend on the application and be in the frequency range 100-200kHz for gases and in a higher MHz frequency range for liquids.

In one embodiment, the flow sensor 1 is a Doppler effect flow sensor 1. In this embodiment, the flow sensor 1 comprises a single piezo trans ducer only. In this case the second piezo transducer 4' can be omitted and the first piezo transducer 4 is used both sending ultrasonic waves 6 and for receiving ultrasonic waves 8. In a Doppler effect type flow sen sor 1, when the transmitted wave 6 is reflected by particles or bubbles in the fluid, its frequency is shifted due to the relative speed of the par ticle. The higher the flow speed of the liquid, the higher the frequency shift between the emitted and the reflected wave.

In one embodiment, the flow sensor 1 is a Doppler effect flow sensor 1 that comprises several piezo transducers 4, 4'. In this case one piezo transducer 4 can be used to transmit an ultrasonic wave 6, while the other piezo transducer 4' can be used to receive the reflected ultrasonic wave 8.

In one embodiment, the flow sensor 1 is a propagation type flow sensor 1. In this embodiment, the flow sensor 1 applies two piezo transducers operating as both transmitter and receiver arranged diagonally to the direction of flow Q. Transmission of ultrasonic waves in the flowing me dium causes a superposition of sound propagation speed and flow speed. The flow speed proportional to the reciprocal of the difference in the propagation times in the direction of the flow Q and in the opposite direction. The propagation type measuring method is independent of the sound propagation speed and thus also the medium. Accordingly, it pos sible to measure different liquids or gases with the same settings.

The temperature sensors 12, 14 and the piezo transducers 4, 4' are connected to the data processor 10. Accordingly, the data processor 10 can process data from the temperature sensors 12, 14 and the piezo transducers 4, 4' and hereby detect the flow based on the data. In the low flow

In Fig. 2A, the second temperature sensor 14 is arranged outside the pipe 2. The second temperature sensor 14 is thermally connected to the pipe 2. Accordingly, the second temperature sensor 14 is capable of measuring the temperature of the pipe 2. The temperature of the pipe 2 will normally correspond to or be very close to the temperature of the fluid 26 in the pipe 2.

In the low flow area below the lower flow level of the flow sensor 1, the flow sensor 1 determines the flow on the basis of the temperature measurements made by the first temperature sensor 12 and the second temperature sensor 14. In fact, below the lower flow level of the flow sensor 1, the flow sensor 1 determines the flow on the basis of the tem perature difference AT _Sf defined as the difference between the tempera tures detected by the first temperature sensor 12 and the second tem perature sensor 14.

(9) AT _Sf = ITs - Tfl where T _s is the temperature of the surroundings measured by the first temperature sensor 12 and T _f is the temperature of the fluid 26 meas ured by the second temperature sensor 14.

Fig. 2B illustrates a schematic view of a clamp-on type flow sensor laccording to the invention. The flow senor 1 shown in Fig. 2B basically corresponds to the one shown in Fig. 2A. The temperature sensor 14, however, is in contact with the fluid 26 inside the pipe 2. A structure extends through the wall of the pipe 2. The temperature sensor 14 is connected to the data processor 10 via a wire extending through said structure. It is indicated that both ultrasonic waves 6, 8 travel a dis tance ¹ /2l_. Accordingly, the total distance of travel is L.

Fig. 3A illustrates a schematic view of a heat energy meter 5 according to the invention. The heat energy meter 5 comprises a flow sensor 1 according to the invention. The flow sensor 1 comprises a housing 20 that is attached to a pipe 2. The flow sensor 1 is arranged and config- ured to detect the flow Q of the fluid 26 (e.g. a water containing liquid) in the pipe 2.

The flow sensor 1 comprises a first temperature sensor 12 arranged to detect the temperature T _s of the surroundings (e.g. the ambient tem perature). The flow sensor 1 comprises a second temperature sensor 14 arranged to detect the temperature T _f of the fluid 26 in the pipe 2. The flow sensor 1 comprises a third temperature sensor 16 arranged to de tect an intermediate temperature T, that is expected to have a value between the ambient temperature T _s and the temperature T _f of the fluid 26.

The flow sensor 1 comprises a first ultrasonic wave generator 4 and a second and a second ultrasonic wave generator 4' formed as piezo transducers 4, 4' that are arranged and configured to generate ultrason ic waves transmitted into the fluid 26 at an angle to the direction of flow Q. The piezo transducers 4, 4' are used in the same manner as shown in and explained with reference to Fig. 2A and Fig. 2B. The flow sensor 1 comprises a data processor 10 connected to the piezo transducers 4, 4' and to the temperature sensors 12, 14, 16. Therefore, the data processor 10 can process data from the temperature sensors 12, 14 and the piezo transducers 4, 4' and hereby detect the flow based on the data.

The third temperature sensor 16 arranged provides temperature meas urements that can be applied to provide an improved estimation of the flow below the lower flow level of the flow sensor 1. The improved esti mation can be accomplished by using two temperature differences: the difference AT _Sf between the surroundings and the fluid 26:

(10) AT _Sf = ITs - Tfl and the temperature difference DT between the intermediate point in the housing 20 and the fluid 26: (11) DT = IT, - T _f l The heat energy meter 5 an external temperature sensor 17 thermally connected to a pipe 3. By measuring the temperature of the fluid in the supply pipe 3 and the temperature of the fluid 26 in the return pipe 2, it is possible to calculate the consumed heat quantity (heat energy). The external temperature sensor 17 may be connected to the data processor 10 by a wired connection as shown in Fig. 3A or by a wireless connec tion as shown in Fig. 3A.

Fig. 3B illustrates a schematic view of another heat energy meter 5 ac cording to the invention. The heat energy meter 5 comprises a flow sen sor 1 according to the invention. The flow sensor 1 basically corre sponds to the one shown in Fig. 3A. The first temperature sensor 12, however, is placed on the outside surface of the housing 20. The heat energy meter 5 an external temperature sensor 17 that is attached to the outside surface of a supply pipe 3. Accordingly, the temperature sensor 17 is thermally connected to the supply pipe 3. By measuring the temperature of the fluid in the supply pipe 3 and the temperature of the fluid 26 in the return pipe 2, it is possible to calculate the consumed heat quantity (heat energy).

Fig. 4A illustrates a schematic view of a clamp-on type flow sensor 1 according to the invention. The flow sensor 1 is mounted on the outside of a pipe 2. The flow sensor 1 comprises a housing 20 having a contact structure that matches the outer geometry of the pipe 2. A thermal connection structure (e.g. a metal layer) is attached to the contact structure. Hereby, the thermal connection structure reduces the thermal resistance and therefore provides an improved and effective heat trans fer between the pipe 2 and the temperature sensors (not shown) of the flow sensor 2.

In one embodiment, the thermal connection structure is a metal foil, coated with thermal adhesive on each side. Such thermal connection structure is capable of provide a permanent bond and reduce the ther mal resistance by filling micro-air voids at the interface. In one embod iment, the thermal connection structure is thermally conductive alumin- ium tape. The thermal connection structure may be thermally conduc tive double-sided structural adhesive aluminium tape.

Fig. 4B illustrates a schematic view of a flow sensor 2 according to the invention. The flow sensor 2 comprises a mechanical flow detection unit 24 that is arranged inside a pipe 3 and thus submerged into the fluid 26.

The flow sensor 1 is a positive displacement meter that requires fluid to mechanically displace components of the mechanical flow detection unit 24 in order to provide flow measurements. The mechanical flow detec tion unit 24 can be a turbine or impeller. The activity and rotational speed of the turbine or impeller can either by using a direct connection to a data processor 10 or by means of a detection member (not shown) arranged and configured to measure the angular velocity og the turbine or impeller. The flow sensor 1 may be a turbine flow meter, a single jet flow meter or a paddle wheel flow meter by way of example. The me chanical flow detection unit 24 constitutes a first detection unit 34. The data processor 10 and the temperature sensors 12, 14 constitute the second detection unit 36.

The flow sensor 1 comprises a first temperature sensor 12 arranged and configured to detect the temperature of the surroundings (the ambient temperature). The flow sensor 1 comprises a second temperature sen- sor 14 arranged and configured to detect the temperature of the fluid 26 inside the pipe 3. The second temperature sensor 14 bears against the outside portion of the wall of the pipe 3. In another embodiment, however, the second temperature sensor 14 may be arranged inside the pipe 3. In a further embodiment, the second temperature sensor 14 may be integrated into the wall of the pipe 3.

The flow sensor 1 comprises a pipe 3 provided with a first flange 18 and a second flange 18'. These flanges 18, 18' are configured to be mechan ically connected to corresponding flanges 19, 19' of two pipes 2, 2'. In one embodiment, the flanges 18, 18' are replaced with similar attach- merit structures designed to attach the flow sensor 1 to pipes 2, 2'.

In one embodiment, the distal portions of the pipes 2, 2' are provided outer threads while the distal portions of the pipe 3 of the flow sensor 3 are provided with corresponding inner threads allowing the pipe 3 to be screwed onto the pipes 2, 2'.

In one embodiment, the distal portions of the pipes 2, 2' are provided inner threads while the distal portions of the pipe 3 of the flow sensor 3 are provided with corresponding outer threads allowing the pipe 3 to be screwed onto the pipes 2, 2'.

Fig. 5A illustrates a schematic view of a flow sensor 1 according to the invention. The flow sensor 1 basically corresponds to the one shown in Fig. 3A.

Fig. 5B illustrates a schematic view of a flow sensor 1 according to the invention. The flow sensor 1 basically corresponds to the one shown in Fig. 3B.

In Fig. 5A and Fig. 5B, the housing 20, however, comprises a portion that bears against the pipe 2, while the second temperature sensor 14 as well as the piezo transducers 4, 4' extends through said portion of the housing 20 in order to be directly connected to the outside portion of the pipe 2, when the flow sensor 1 is attached to the pipe 2. It is possible to apply clamping structures such as cable tie or hose clamps to clamp the flow sensor to the pipe 2.

The piezo transducers 4, 4' constitute a first detection unit 34. The data processor 10 and the temperature sensors 12, 14, 16 constitute the second detection unit 36.

The flow sensor 1 according to the invention uses the fact that the fluid 26 in most cases transports heat between the physical zones it flows through and that these physical zones have different temperatures. By detecting the temperature difference between these zones, it is possible to provide an alternative measure for the flow rate.

Accordingly, the flow sensor 1 and the method according to the inven tion can detect flow in the low flow range, in which the prior art flow sensors cannot detect any flow.

Moreover, the flow sensor 1 and the method according to the invention can provide an improved (more accurate) flow detection in general by using the temperature difference between the above-mentioned zones.

The heat transfer rate q (corresponding to E/t) from the fluid to the sur roundings is defined in the following equation (12):

(12) q — U T^ where AT _Sf is the temperature difference between the surroundings and the fluid 26; A is the surface area where the heat transfer takes place and U is the heat transfer coefficient.

The heat transfer coefficient U is defined in the following equation (13): where k is the thermal conductivity of the material through which the heat transfer takes place and s is the thickness of the material through which the heat transfer takes place.

The working principle of a Doppler Effect flow sensor 1 is shown in and briefly explained with reference to Fig. 6A. Doppler Effect flow sensors are affected by changes in the sonic velocity of the fluid 26. Accordingly, Doppler Effect flow sensors are sensitive to changes in density and tem perature of the fluid 26. Therefore, many prior art Doppler Effect flow sensors are unsuitable for highly accurate measurement applications. The invention, however, makes it possible to detect the temperature and speed of sound of the fluid 26 and compensate for temperature and fluid (density) changes and thus provide an improved accuracy. Like wise, the invention, makes it possible to detect the density of the fluid 26 (via measurement made on a sample of the fluid 26) and compen- sate for temperature and/or fluid (density) changes in order to even fur ther improve the accuracy of the flow sensor 1.

The Doppler Effect flow sensor 1 is a time-of-flight ultrasonic flow sen sor that measures the time for the sound to travel between a transmit ter 4 and a receiver 4'. In a typical setup, like the one illustrated in Fig. 6A, two transducers (transmitters/receivers) 4, 4' are placed on each side of the pipe 2 through which the flow Q is to be measured. The transmitters 4, 4' transmit pulsating ultrasonic waves 6 in a predefined frequency from one side to the other. The average fluid velocity V is proportional to the difference in frequency.

Accordingly, the fluid velocity V can be expressed as: where ti is the transmission time for the transmission time downstream, t2 is the transmission time upstream, L is the distance between the transducers and f is the relative angle between the transmitted ultra sonic beam 6 and the fluid flow Q.

The flow Q can be calculated as the product between the fluid velocity V and the cross-sectional area A _Pipe of the pipe 2: the speec of sound c is given by the following equation

The flow sensor 1 shown in Fig. 6A comprises a first temperature sensor 12 arranged to detect the ambient temperature (the temperature in the surrounding of the pipe 2. The flow sensor 1 comprises a second tem perature sensor 14 arranged to detect the temperature of the fluid 26. The flow sensor 1 comprises a data processor 10. Even though it is not shown in Fig. 6B, the temperature sensors 12, 14 and the two transduc ers 4, 4' are connected to the data processor 10. Accordingly, the data processor 10 can process data and calculate the flow Q based on data from the temperature sensors 12, 14 and the two transducers 4, 4'.

The working principle of a Doppler Effect flow sensor 1 measuring the flow in a fluid containing particles 32 fluids shown in and briefly ex plained with reference to Fig. 6B. The fluid velocity V can be calculated by using the following equation (17): it)

(18) ( f) where fr is the frequency of the received wave; ft is the frequency of the transmitted wave; f is the relative angle between the transmitted ultrasonic beam and the fluid flow Q and c is the velocity of sound in the fluid 26. The flow Q can be calculated as the product between the fluid velocity V and the cross-sectional area A _Pipe of the pipe 2: Equation 15 and 16 can also be used when calculating the flow by using the flow sensor shown in Fig. 2A, Fig. 2B, Fig. 3A and Fig. 3B.

Fig. 7 illustrates a graph depicting the speed of sound c in water as function of the temperature T of the water. Similar graphs can, howev- er, be made for other liquids. In the following, water is just representing on possible fluid and water may be replaced with another liquid.

If the dimensions of the tubular structure (e.g. pipe, through which a flow Q of water is flowing, are not known, an estimation of the distance L that the sound travels in the water is needed. This problem is in par- ticular relevant for ultrasonic clamp-on sensors. Over time, sediments may be provided at inside surface of a pipe. This will gradually decrease the distance L. Accordingly, the invention makes it possible to estima tion of the distance L under such conditions. By determining the speed of sound c in the water, is possible to esti mate the distance L and hereby improve the accuracy of the detected speed V and flow Q of the water. Accordingly, changes in the speed of sound c in the water is highly relevant. When the speed of sound c is detected, it is possible to calculate the distance L that the sound travels in the water.

The speed of sound c is given by the following formula (12):

Where K is the Bulk Modulus of Elasticity and p is the density.

Since the density of water depend on the temperature T, the speed of sound c depends on the temperature T. Moreover, the speed of sound c depends on the concentration of substances (e.g. glycol) in the water.

When the inclination angle a is known, the average speed V of the water (in the tube measured by delta time of flight) can be by using the fol lowing equation (19):

When the speed of sound c is known. L can be calculating or estimated by using the following equation (16) (since ti and t2 are being meas ured).

Accordingly, the flow Q can be calculated as the product between the average speed V of water and the cross-sectional area A _Pipe of the pipe 2:

The measured fluid temperature T and the measured time-of-flight can be used to determine the density p and the speed of sound c by using equation (18).

If the flow sensor is calibrated in pure water at a temperature T ₂ of 26°C, Fig. 7 shows that the speed of sound c(T ₂ ) is 1500 m/s. If a lower temperature Ti of 21.5°C is detected, the speed of sound c(Ti) is 1485 m/s. Accordingly, by calibrating the flow sensor by using a fluid (e.g. a liquid such as water) at a known temperature T and density p, a simple temperature measurement is sufficient to detect the speed of sound c by using equation (18).

The specific heat capacity of the fluid (e.g. water) depends on the con tent of additional substances (e.g. sugar, salt, ethylene glycol, glycerol or propylene glycol).

When the speed of sound c is known, it is possible to calculate the spe cific heat capacity of the fluid (e.g. water) having additional substances on the basis of the detected density of the fluid. Hereby, it is possible to make a heat energy meter having a flow sensor according to the inven tion more accurate.

It may be an advantage to measure content of additional substances (e.g. sugar, salt, ethylene glycol, glycerol or propylene glycol). Hereby, it would be possible to calibrate the flow sensor on the basis of the measurements.

Example 1

If the flow sensor being used in pure water detects a flow Q of 1 li ter/minute at a temperature T ₂ of 26°C, Fig. 7 shows that the speed of sound c(T ₂ ) is 1500 m/s.

When the speed of sound c (1500 m/s) is known. L can be calculating by using the following equation (16) (since ti and t ₂ are detected by the flow sensor).

When the flow sensor is used at a later point in time, the expected speed of sound c, at the same temperature T ₂ of 26°C would be 1500 m/s. If, however, the detected speed of sound c is 1485 m/s calculated by using equation (16) and the known L, the decreased speed of sound is approximately 1 %. This may be caused by a change in the density p of the water. If we presume that the Bulk Modulus of Elasticity K is con- stant, equation (18) will give us that the density p is increased with ap proximately 2 % (by using equation 18).

If the flow sensor is used in a heat energy meter, it would be possible to correct the specific heat capacity of the water based on the detected density of the water. It can be concluded that the content of additional substances (e.g. sugar, salt, ethylene glycol, glycerol or propylene gly col) has increased. Accordingly, it is possible to improve the accuracy of the heat energy meter. This is relevant since the content of additional substances (e.g. sugar, salt, ethylene glycol, glycerol or propylene gly- col) may vary as function of time. If the flow sensor is configured to au tomatically detect changes in the density of the fluid, the flow sensor is used in a heat energy meter will be capable of providing a high accuracy even when the content of additional substances varies over time. Fig. 8 illustrates a graph depicting the flow Q detected by means of a flow sensor according to the invention as function of the temperature difference AT _Sf .

The lower flow level Q _A represents the lowest flow that can be measured by using prior art flow sensors. Prior art flow sensors are not capable of detecting flow below the lower flow level Q _A , the flow sensor and meth od according to the invention, however, is capable of providing flow measurements below this lower flow level Q _A .

Above a base flow level Q _B the graph shows that the temperature differ ence AT _Sf is constant and thus independent of the flow Q.

In the flow-calibration-area B ₂ between the lower flow level Q _A and the base flow level Q _B the temperature difference J _Sf increases as function of the flow Q. In this flow-calibration-area B ₂ , a first flow sensor meas urement Mi and a second flow sensor measurement M ₂ are indicated.

These flow sensor measurements Mi and M ₂ are made in the flow- calibration-area B ₂ in order to determine the parameters required to de termine how the flow Q depends on the temperature difference J _Sf in the flow-calibration-area B ₂ and in the flow area Bi below the flow- calibration-area B ₂ . The relationship between the flow Q and tempera ture difference AT _Sf is given by equation (2):

(2)

It is possible to measure temperature differences DTi, DT _M 3 and DT ₂ and calculate the flow Q by using equation (2).

List of reference numerals

1 Flow sensor

2, 2', 3 Pipe 4, 4' Ultrasonic transducer (piezo transducer)

5 Heat energy meter

6 Ultrasonic vibration wave 8 Reflected ultrasonic vibration wave

10 Data processor (e.g. a micro-processor)

12 Temperature sensor

14 Temperature sensor

16 Temperature sensor

17 Temperature sensor

18, 18' Flange 19, 19' Flange 20 Housing 22 Thermal connection structure (e.g. a metal layer) 24 Mechanical flow detection unit 26 Fluid 28 Graph 30 Low flow area 32 Particle

34, 36 Detection unit

Ts Temperature of the surroundings

T _f Temperature of the fluid

DT Temperature difference

AT _Sf Temperature difference between the surroundings and the fluid

DTi, DT ₂ Temperature difference

DTA, DTB Temperature difference

Ti,T ₂ Temperature

Mi, M _2, M ₃ Flow measurement

Bi Flow area

B ₂ Flow-calibration-area

Cp Specific heat capacity k Thermal conductivity U Coefficient of heat transfer

A Surface area

W Volume t Time-of-flight t' Temperature compensated time-of-flight

At Delta-time-of-flight t _l , t.2 Time-of-flight DTi, DT ₂ Temperature difference DTA, DTB Temperature difference DTMI, DTM2 Temperature difference DTM3 Temperature difference d Thickness Q Flow

QI, Q2 Flow QA, QB Flow QMI, QM2 Flow QM3 Flow V Fluid velocity

Angle L Distance