Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination
Precise flow measurement is crucial in fluid power systems. Especially in combination with pressure, hydraulic power can be particularly beneficial for predictive maintenance and control applications. However, conventional flow sensors in fluid power systems are often invasive, thus disrupting the f...
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MDPI AG
2025-03-01
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| Series: | Journal of Experimental and Theoretical Analyses |
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| author | Faras Brumand-Poor Tim Kotte Abdulaziz Hanifa Christian Reese Marius Hofmeister Katharina Schmitz |
| author_facet | Faras Brumand-Poor Tim Kotte Abdulaziz Hanifa Christian Reese Marius Hofmeister Katharina Schmitz |
| author_sort | Faras Brumand-Poor |
| collection | DOAJ |
| description | Precise flow measurement is crucial in fluid power systems. Especially in combination with pressure, hydraulic power can be particularly beneficial for predictive maintenance and control applications. However, conventional flow sensors in fluid power systems are often invasive, thus disrupting the flow and yielding unreliable measurements, especially under transient conditions. A common alternative is to estimate the flow rate using pressure differentials along a pipe and the Hagen–Poiseuille law, which is limited to steady, laminar, and incompressible flows. This study advances a previously introduced analytical soft sensor, demonstrating its ability to accurately determine the transient pipe flow beyond laminar conditions, without requiring a dedicated flow rate sensor. This method provides a robust and computationally efficient solution for real-world hydraulic systems by applying two pressure transducers. A key contribution of this work is the investigation of signal filtering, revealing that even a simple first-order low-pass filter with a 100 Hz cutoff frequency significantly improves accuracy, which is demonstrated for pulsation frequencies of 5, 10, and 15 Hz, where the filtered results closely match experimental data from a test rig. These findings underscore the soft sensor’s potential as a reliable alternative to traditional flow sensors, offering high accuracy with minimal computational overhead for a wide range of flow conditions. |
| format | Article |
| id | doaj-art-252efd1039c94ac2b56f2cd59e733a5c |
| institution | OA Journals |
| issn | 2813-4648 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | MDPI AG |
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| series | Journal of Experimental and Theoretical Analyses |
| spelling | doaj-art-252efd1039c94ac2b56f2cd59e733a5c2025-08-20T01:48:56ZengMDPI AGJournal of Experimental and Theoretical Analyses2813-46482025-03-0131810.3390/jeta3010008Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate DeterminationFaras Brumand-Poor0Tim Kotte1Abdulaziz Hanifa2Christian Reese3Marius Hofmeister4Katharina Schmitz5Institute for Fluid Power Drives and Systems (ifas), RWTH Aachen University, 52074 Aachen, GermanyInstitute for Fluid Power Drives and Systems (ifas), RWTH Aachen University, 52074 Aachen, GermanyInstitute for Fluid Power Drives and Systems (ifas), RWTH Aachen University, 52074 Aachen, GermanyInstitute for Fluid Power Drives and Systems (ifas), RWTH Aachen University, 52074 Aachen, GermanyInstitute for Fluid Power Drives and Systems (ifas), RWTH Aachen University, 52074 Aachen, GermanyInstitute for Fluid Power Drives and Systems (ifas), RWTH Aachen University, 52074 Aachen, GermanyPrecise flow measurement is crucial in fluid power systems. Especially in combination with pressure, hydraulic power can be particularly beneficial for predictive maintenance and control applications. However, conventional flow sensors in fluid power systems are often invasive, thus disrupting the flow and yielding unreliable measurements, especially under transient conditions. A common alternative is to estimate the flow rate using pressure differentials along a pipe and the Hagen–Poiseuille law, which is limited to steady, laminar, and incompressible flows. This study advances a previously introduced analytical soft sensor, demonstrating its ability to accurately determine the transient pipe flow beyond laminar conditions, without requiring a dedicated flow rate sensor. This method provides a robust and computationally efficient solution for real-world hydraulic systems by applying two pressure transducers. A key contribution of this work is the investigation of signal filtering, revealing that even a simple first-order low-pass filter with a 100 Hz cutoff frequency significantly improves accuracy, which is demonstrated for pulsation frequencies of 5, 10, and 15 Hz, where the filtered results closely match experimental data from a test rig. These findings underscore the soft sensor’s potential as a reliable alternative to traditional flow sensors, offering high accuracy with minimal computational overhead for a wide range of flow conditions.https://www.mdpi.com/2813-4648/3/1/8soft sensorvolumetric flow rate determinationnon-laminar flowsignal filtering |
| spellingShingle | Faras Brumand-Poor Tim Kotte Abdulaziz Hanifa Christian Reese Marius Hofmeister Katharina Schmitz Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination Journal of Experimental and Theoretical Analyses soft sensor volumetric flow rate determination non-laminar flow signal filtering |
| title | Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination |
| title_full | Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination |
| title_fullStr | Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination |
| title_full_unstemmed | Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination |
| title_short | Advancing Pressure-Based Flow Rate Soft Sensors: Signal Filtering Effects and Non-Laminar Flow Rate Determination |
| title_sort | advancing pressure based flow rate soft sensors signal filtering effects and non laminar flow rate determination |
| topic | soft sensor volumetric flow rate determination non-laminar flow signal filtering |
| url | https://www.mdpi.com/2813-4648/3/1/8 |
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