FLUID FLOW RATE SENSOR AND METHOD OF OPERATION

FIELD

[0001] The present disclosure generally relates to fluid flow rate sensors, and more particularly to thermo-anemometers and their methods of operation.

BACKGROUND [0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Fluid delivery systems may include fluid flow meters to measure the flow rate of the fluid in the fluid delivery systems, and thus to determine the volume of the fluid to be dispensed based on the flow rate. Thermo- anemometers have been commonly used for measuring the fluid flow rate over turbine and/or paddlewheel sensors for their lack of moving parts, which are sensitive to contamination of the fluid. A thermo-anemometer operates based on the principles of heat transfer and typically includes a bridge circuit having a resistive heating element subjected to the stream of fluid flow. As the fluid flow passes over the resistive heating element, the fluid carries away heat, resulting in a temperature drop in the resistive heating element. The flow rate of the fluid can be determined by measuring the heat loss from the heating element to the fluid.

[0004] In one method, the power to the heating element is increased after a temperature drop occurs in the bridge circuit to bring the heating element back to its starting temperature (constant-temperature type). The increased power gives an indication of the fluid flow rate. Another method involves correlating the voltage drop across the bridge circuit to determine the flow rate (constant-current type).

[0005] In either method, the conventional thermo-anemometers have limitations in response time. The flow rate can not be accurately measured until the fluid flow, and hence the signals indicative of the fluid flow rate, reach a steady state. Some thermo-anemometers may require a relatively long time

period to measure the flow rate of the fluid.

[0006] Another issue with the thermo-anemometers is the need for temperature compensation and part-to-part calibration. A lower temperature fluid has a greater capacity to remove heat from the resistive heating element than a higher temperature fluid at the same flow rate. Therefore, temperature compensation is generally required. Part-to-part calibration may require expensive software and may be difficult to implement in a manufacturing environment.

SUMMARY

[0007] Several embodiments of the present disclosure provide for fluid flow rate sensors which can more accurately and quickly determine the fluid flow rate, and which are self-calibrated and temperature compensated. In one form, a fluid flow rate sensor for detecting a flow rate of a fluid includes a probe module, a look-up table and a control module. The probe module generates a first signal corresponding to an output voltage and a second signal corresponding to a temperature of the fluid. The look-up table includes empirical data of a relationship among the output voltage of the detection circuit, the temperature of the fluid, and the flow rate of the fluid. The control module determines the flow rate of the fluid based on the first signal, the second signal, and the look-up table.

[0008] In another form, a fluid flow rate sensor for detecting a flow rate of a fluid includes a bridge circuit for generating an output voltage, a temperature sensing circuit for detecting a temperature of the fluid, a heating circuit for heating at least one thermistor of the bridge circuit and a control module. The bridge circuit, the temperature sensing circuit and the heating circuit are connected in parallel. The output voltage is a function of the temperature and the flow rate of the fluid. The control module determines the flow rate of the fluid based on a look-up table which indicates a relationship among the flow rate of the fluid, the temperature of the fluid and the output voltage of the bridge circuit based on empirical data.

[0009] In yet another form, a method of operating a fluid flow rate

sensor comprising a detection circuit is provided and includes measuring a temperature of the fluid, measuring a voltage output of the detection circuit, and determining the fluid flow rate based on a look-up table. The look-up table indicates a relationship among the output voltage of the detection circuit, the temperature of the fluid, and a flow rate of the fluid.

[0010] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0011] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0012] Figure 1 is a schematic block diagram of a fluid flow rate sensor according to the present disclosure;

[0013] Figure 2 is a perspective view of an exemplary probe module of a fluid flow rate sensor according to the present disclosure;

[0014] Figure 3 is a front view of an exemplary probe module of a fluid flow rate sensor according to the present disclosure; [0015] Figure 4 is a top view of an exemplary probe module of a fluid flow rate sensor according to the present disclosure;

[0016] Figure 5 is a front view of a printed circuit board including an exemplary detection circuit of a fluid flow rate sensor according to the present disclosure; [0017] Figure 6 is a rear view of a printed circuit board including an exemplary detection circuit of a fluid flow rate sensor according to the present disclosure;

[0018] Figure 7 is a schematic circuit diagram for an exemplary detection circuit for a fluid flow rate sensor according to the present disclosure; [0019] Figure 8 is a flow chart describing the operation of a fluid flow rate sensor according to the present disclosure;

[0020] Figure 9 is an exemplary graph plotting the temperature

response over time for a fluid flow rate sensor according to the present disclosure;

[0021] Figure 10 is a graph showing the relationship among a flow rate, an output voltage, and the fluid temperature and illustrating the content of a two-dimensional look-up table for use in one embodiment of a fluid flow rate sensor according to the present disclosure;

[0022] Figure 11 is a schematic circuit diagram of another exemplary detection circuit for a fluid flow rate sensor with temperature compensation circuitry, according to the present disclosure; and [0023] Figure 12 is a graph showing the relationship between a flow rate and an output voltage, and the fluid temperature and illustrating the content of a one-dimensional look-up table for use in an embodiment of a fluid flow rate sensor with temperature compensation according to the present disclosure.

[0024] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0025] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. [0026] Figure 1 generally depicts the major components of a fluid flow rate sensor 10 according to the present disclosure. The fluid flow rate sensor 10 may be employed in a household appliance such as, for example, a refrigerator, washing machine, dishwasher, water dispenser, or automatic ice maker, to monitor water flow therein. [0027] The sensor 10 generally includes a probe module 12, a control module 14, and, optionally, an I/O module 16. The probe module 12 is coupled to the control module 14. As used in this description, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.

[0028] When the probe module 12 is subjected to the flow of a fluid 11 ,

the probe module 12 undergoes a changed condition and generates electrical signals 13 corresponding to such changes. The signals 13 are continuously sent to the control module 14 for processing, which, in turn, generates an output 15 indicative of a fluid flow rate. The I/O module 16 provides a means by which the fluid flow rate sensor 10 can communicate its output 15 to other device(s) or a user.

[0029] Referring to Figures 2 through 6, the probe module 12 includes a probe portion 17 and a housing portion 18 for mounting the probe portion 17 to a fluid source. The housing portion 18 includes a body 19, a pair of tubes 20 formed at opposing ends of the body 19, a cover 21 secured to the body 19 by screws 22. The body 19 defines a chamber 23 (shown in Figure 4) and the tubes 20 define a passageway 24 extending along a longitudinal axis of the tubes 20. The chamber 23 is in fluid communication with the passageway 24. The tubes 20 may be provided with annular flanges 25 at their free ends to facilitate connection of the tubes 20 to the fluid source, such as the flexible supply hose of a water dispenser, for example.

[0030] The probe portion 17 is inserted into the chamber 23 of the body 19 through the cover 21. The probe portion 17 is a thermo-anemometer and includes a substrate 26 (shown, for example, in Figures 5 and 6) on which is disposed a detection circuit 32. The substrate 26 lies in the chamber 23 and a cable portion 28 is connected to the substrate 26. The cable portion 28 extends to outside of the chamber 23 and is electrically connected to the control module 14.

[0031] The substrate 26 may be a printed circuit board on which a detection circuit 32 (such as the example shown in Figures 5-7) is deposited. The substrate 26 is subjected to the flow of fluid 11 that is intended to be monitored. A thin vacuum-deposited Parylene coating may be deposited on the surfaces of the substrate 26 to reduce the thermal mass of the substrate 26.

[0032] The probe module 12 may have varied electrical characteristics depending on the arrangement of the detection circuit 32 on the substrate 26. By unscrewing the screws 22 and removing the cover 21 from the body 19, the probe portion 17 may be interchanged with another probe portion 17 having

different electrical characteristics so that the probe module 12 may be more suitable for other fluids and/or other operating conditions. Moreover, when the probe module 12 ceases to provide the desired function, only the probe portion 17 needs to be replaced. Therefore, it is expected that the probe module 12 of the present disclosure can result in a reduction in replacement and/or component costs.

[0033] One exemplary detection circuit 32 that can be employed in the fluid flow rate sensor according to the present disclosure is shown in Figures 5, 6 and 7. In Figure 7, a schematic circuit diagram for the detection circuit 32 is shown. Figures 5 and 6 illustrate a physical embodiment of the detection circuit 32 on the substrate 26.

[0034] The substrate 26 contains the detection circuit 32 on its two sides. The substrate 26 has pin connectors P1 , P2, P3, P4 and P5 to which the cable portion 28 is connected at end 30. The detection circuit 32 (Figure 7) includes a bridge circuit 34, a heating circuit 36, and a temperature sensing circuit 38. The bridge circuit 34 includes four thermistors NTC1 , NTC2, NTC3 and NTC4 screen-printed on a front side 40 of the substrate 26. The heating circuit 36 includes a heating resistor 1 R1 screen-printed on a back side 42 of the substrate 26. The heating resistor 1 R1 on the back side 42 is disposed in close proximity to thermistors NTC1 and NTC2 on the front side 40 to heat thermistors NTC1 and NTC2 during operation. NTC3 and NTC4 are physically located further away and upstream from heating resistor R1 such that they are not heated by the heating resistor R1 during operation. The temperature sensing circuit 38 includes a fixed resistor R2 and a thermistor NTC5 screen-printed on the back side 42 of the substrate 26 and adjacent to thermistors NTC3 and NTC4 on the front side 40. Thermistors NTC1 , NTC2, NTC3, NTC4 and NTC5 have negative temperature coefficient. The thermistor NTC5 and the fixed resistor R2, are also disposed upstream from the heating resistor R1 and the heated thermistors NTC1 and NTC2. [0035] As shown in Figure 7, the bridge circuit 34, the heating circuit

36 and the temperature sensing circuit 38 are connected in parallel. The bridge circuit 34 is a four-wire bridge circuit having a first leg and a second leg

connected in parallel. The thermistor NTC1 is coupled in series with the thermistor NTC3 to form the first leg. The thermistor NTC2 is coupled in series with the thermistor NTC4 to form the second leg. The two thermistors NTC2 and NTC4 may be properly chosen to have a temperature coefficient β and room temperature resistance Ro smaller than that of thermistor NTC1 and NTC3 so that the bridge circuit 34, the function of which is to measure fluid flow rate, becomes much less sensitive to the fluid temperature.

[0036] The substrate 26 may be formed from a highly thermally conductive ceramic upon which is screen printed a ceramic-filled carbon paste material that forms the thermistors NTC 1 through NTC5. Such material is available from Heraeus Incorporated, Circuit Materials Division under the R100 Series designation. Such a configuration completely eliminates discrete thermistor components and helps to reduce the thermal mass of the probe module 12. [0037] The heating circuit 36 is connected in parallel to the two legs of the bridge circuit 34. The heating resistor R1 may have a rating of as high as 4 to 6 watts, and as low as 0.5 to 1.5 watts. It should be understood that more than one heating resistor in parallel or in series may be provided in the heating circuit 34 without departing from the spirit of the present disclosure. [0038] The temperature sensing circuit 38 includes thermistor NTC5 and the fixed resistor R2 formed as a voltage divider. The temperature sensing circuit 38 is connected in parallel to the bridge circuit 34 for measuring the temperature of the fluid upstream from the heating resistor R1.

[0039] The values for the various components in the detection circuit 32 shown in Figure 7 are as follows:

[0040] The detection circuit 32 includes conductive traces 56, 58, 60, 62, 64 that lead to a plurality of pin connectors P1 , P2, P3, P4, and P5, respectively. The pin connectors P1 , P2, P3, P4 and P5 are provided at the end 30 (Figures 5 and 6) of the probe module 12.

[0041] The conductive trace 56 is disposed adjacent to NTC1 and

NTC4 of the bridge circuit 34 and is grounded at pin connector P1. The conductive trace 58 is coupled to the second leg of the bridge circuit 34 at terminal 66 between thermistors NTC2 and NTC4. The conductive trace 60 is connected to the temperature sensing circuit 38 at terminal 68 between the thermistor NTC5 and the fixed resistor R2. The conductive trace 62 is connected to the bridge circuit 34 at terminal 70 adjacent to thermistors NTC2 and NTC3. The conductive trace 64 is coupled to the first leg of the bridge circuit 34 between thermistor NTC1 and thermistor NTC3.

[0042] An input voltage V _in (for example, 12 V _D c) may be applied through pin connector P4 at terminal 70 to energize the detection circuit 32. An output voltage V _ou t is measured across terminals 66 and 72 and can be read at pin connectors P2 and P5. A reference voltage V _τ representative of temperature of the fluid can be measured at pin connector P3.

[0043] Referring to Figures 8 through 10, before the initiation of the

fluid flow, an input voltage V _in is applied to the detection circuit 32 so that the heating circuit 36 can preheat thermistors NTC1 and NTC2 to a predetermined elevated temperature. The thermistors NTC3 and NTC4 are not heated due to physical separation between them and heating resistor R1. As shown in Figure 9, as soon as the detection circuit 32 is energized, the detection circuit 32 generates an output voltage of δV _0U t across the bridge circuit 36 read at pin connectors P2 and P5. δV _0Ut is an offset voltage indicating an imbalance in the four-wire bridge circuit 34. To use a bridge circuit to measure the fluid flow rate, a balanced bridge circuit 34 (i.e., zero output voltage) is generally required before the initiation of the fluid flow. This offset voltage is a result of manufacturing deviations from the designed specifications for one or more components of the detection circuit 32. Instead of calibrating the individual components of the detection circuit 32, this offset voltage δV _out can be stored in the control module 14 and added to or subtracted from a look-up table, which will be described later. Therefore, factory calibration of the individual components may not be necessary.

[0044] During this preheating period, as the thermistors NTC1 and NTC2 are heated, the resistance of the thermistors NTC1 and NTC2 is decreased and the output voltage V _ou t is increased. The rate of the temperature rise of the thermistors NTC1 and NTC2 is monitored and recorded so that a signal corresponding to the rate of temperature rise is transmitted to the control module 14. This pre-heating time is about 250 ms. Because the substrate 26 has a low-thermal-mass Parylene coating, it does not take long to heat the thermistors NTC1 and NTC2 to the predetermined elevated temperature. [0045] When the thermistors NTC1 and NTC2 reach the predetermined elevated temperature, a valve which controls the fluid is opened and the fluid flow is initiated at time=zero seconds as shown in Figure 9. As soon as the fluid is initiated, the probe module 12 is subjected to a stream of fluid, which absorbs the heat of the thermistors NTC1 and NTC2, resulting in a rapid temperature drop in the thermistors NTC1 and NTC2. The output voltage V _0Ut also drops rapidly. The fluid flow is required to reach a steady-state condition before the control module 14 begins to estimate the volume of water

that has been dispensed. The time required to reach steady-state depends on the flow rate of the fluid. The faster the fluid flow, the less time required to reach a steady state. During the period that the fluid flow has not reached a steady state condition, the control module 14 may assume a constant fluid flow rate (e.g., a flow rate corresponding to the flow rate first measured after reaching a steady state).

[0046] Due to the low thermal mass Parylene coating on the substrate 26, it does not take long to reach a steady state (typically, about 500 msec). At the steady state, the temperature of the fluid is determined from the output voltage VT read at power connector P3 in a well-known manner. The output voltage V _out is a function of the fluid flow rate and the fluid temperature and is read at P2 and P5. The output voltages V _out and V _τ of the detection circuit 32 may be sampled by the control module 14 at discrete time intervals (e.g., 10 ms).

[0047] After the data regarding the fluid temperature and the output voltage V _out are recorded, the control module 14 determines the fluid flow rate according to a look-up table.

[0048] Figure 10 graphically illustrates an exemplary two-dimensional look-up table used by the control module 14 to determine the flow rate of water. This graph shows a plurality of curves, each indicating a relationship between the output voltage of the bridge circuit 34 and the fluid flow rate at a given fluid temperature. Each of the curves were generated from data points (x=flow rate, y=V _O u _t ) that were obtained in a laboratory under controlled conditions (e.g., flow rates and fluid temperatures). A curve was then fit to the data points in a well- known manner. Using the look-up table, the fluid flow rate can readily be determined when the output voltage V _ou t and fluid temperature VT are measured or read by the control module 14.

[0049] Figure 11 illustrates another embodiment of a detection circuit 100 for use with a fluid flow rate sensor of the present disclosure, this one incorporating temperature compensation circuitry. The detection circuit 100 in this embodiment is generally similar to the detection circuit 32 of Figure 7, except that it includes a temperature compensation circuit and the temperature sensing circuit may be optional, as desired. More specifically, the detection circuit 100

including a first bridge circuit 102, a second bridge circuit 104, a heating circuit 106 connected in parallel. The first bridge circuit 102 includes four thermistors NTC1 , NTC2, NTC3 and NTC4 for the purpose of measuring the fluid flow rate. The first bridge circuit 102 has two legs, with each leg including two thermistors. The arrangement of the first bridge circuit 102 and the heating circuit 106 of this embodiment is similar to that of the bridge circuit 34 and the heating circuit 36 in Figure 7. The second bridge circuit 104 includes compensating resistors Rcompi , Rcomp2, Rcomp3 and Rcomp4 which are connected in parallel with respective bridge thermistors NTC1 , NTC2, NTC3 and NTC4, respectively. This arrangement functions as a temperature compensation circuit. The second bridge circuit 104 includes two legs, with each leg having two compensating resistors. The compensating resistors Rcompi through Rcomp4 can be deposited (e.g., by screen-printing) directly on the substrate 26, or externally connected to the four wire bridge circuit (e.g., as part of the control module 14). [0050] Optionally, the detection circuit 100 may include a temperature sensing circuit 108 including a thermistor NTC5 and a fixed resistor R2. As in the detection circuit 32 of Figure 7, the temperature sensing circuit 108 may be provided upstream of the heating circuit 106. In this embodiment, however, the measurement of the fluid temperature by the temperature sensing circuit 108 is not necessary for determining the fluid flow rate as discussed above. The temperature sensing circuit 108 is optional and provides an output V _τ corresponding to the fluid temperature, if desired.

[0051] In a fluid flow rate sensor having temperature compensation, only a one-dimensional look-up table is required to determine fluid flow rate, because fluid temperature is removed as a variable under consideration. For the detection circuit 100, having values for the thermistors NTC1 , NTC2, NTC3 and NTC4 and compensating resistors Rcompi , Rcomp2, Rcomp3 and Rcomp4 as set forth in the table below, Figure 12 illustrates the value for V _out at a given fluid flow rate within the range of 0.1 to 1.3 GPM for fluid temperatures of 0.5 ⁰ C, 25 ⁰ C and 50 ⁰ C.

[0052] As shown in Figure 12, the output voltage V _out is independent of the temperature of the fluid. As a result, the control module 12 requires less memory storage space for the one-dimensional look-up table than is required in a control module for a fluid flow rate sensor not having temperature compensation. The fluid flow rate sensor having temperature compensation also eliminates the need for software that provides temperature compensation, it improves measurement speed, and reduces overall system costs.

[0053] While the fluid flow sensor response shown in Figures 10 and 12 are for water, the flow rate of other fluids may, of course, be measured by the device according to the present disclosure. Such other fluids would each have corresponding look-up tables of data for use in the device.

[0054] As previously set forth, if the fluid flow rate sensor 10 has an offset voltage δV _out immediately after the detection circuit 32 is energized, the detection circuit 32 may need to be calibrated. The calibration may be achieved by adding/subtracting the offset voltage δV _ou t to/from the output voltage of the look-up table.

[0055] In addition to determining the fluid flow rate, the sensor of the present disclosure can be used to determine a fault condition of the sensor. During the preheating period and upon initiation of the fluid flow, the rate of the temperature rise of the sensor is monitored and recorded. When the rate of the

temperature rise is excessive (e.g., above a pre-determined threshold value), the control module 14 may determine that the fluid flow rate sensor 10 is in a dry condition (i.e., not subjected to the fluid flow). The control module 14 may generate a fault condition and may de-energize the fluid flow rate sensor 10. Alternatively, or in addition, other appliances and/or components may be shut down due to the dry condition.

[0056] It should be appreciated that the number of thermistors and heating resistors may vary depending on the application for the fluid flow rate sensor. Also, the heating circuit may include more than one heating resistor connected in series or in parallel. Furthermore, heating resistor(s) and the(ir) corresponding voltage source may be omitted altogether in applications where the thermistor(s) can be internally self-heated.

[0057] This description is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the invention.