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Ultrasonic flow measurement ExactSonic P for test bench applications

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Ultrasonic flow measurement ExactSonic P for test bench applications

Ultrasonic flow measurement ExactSonic P for test bench applications

What is ultrasonic flow measurement?

Ultrasonic flow measurement is an advanced, non-contact technique for determining flow velocities and volumetric flow rates in pipes.

It's based on the transit-time difference method: ultrasonic pulses are transmitted in both directions - with and against the flow. The difference in the transit times of these signals allows for the precise determination of the medium's flow velocity. This method offers the advantage of having no moving parts, resulting in high reliability and durability.

Ultrasonic flow measurement is particularly suitable for applications where no mechanical influence on the medium is desired, as it operates without direct contact with the flowing medium. This prevents wear and measurement errors caused by the medium itself.

ExactSonic P: High-Performance Ultrasonic Flow Meter for Test benches

The ExactSonic P from Höntzsch is a state-of-the-art ultrasonic flow meter designed specifically to meet the requirements of test bench applications. Using the transit-time difference method flow velocities can be measured  with high precision. Ultrasonic pulses are transmitted alternately in the direction of flow and against it, and the difference in transit times is used to calculate the average flow velocity

An integrated transducer combines this velocity with the pipe cross-section to calculate the volumetric flow rate. In addition, pressure and temperature are measured to accurately determine the standard volumetric flow rate or mass flow rate. As a result, the ExactSonic P delivers reliable and precise flow measurements that are critical in many test bench applications. 

Thanks to continuous real-time data monitoring, the Exactsonic P allows more precise control of test processes, thereby helping to optimize test bench efficiency. The ExactSonic P's integrated ultrasonic flow sensor ensures continuous, high precision measurement of flow velocity in real time.

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Installation und Assembly

The ExactSonic P is typically installed in a measuring tube with an inner diameter of 50 to 300 mm. Depending on the requirements, the device can be mounted using a conical or intermediate flanges as well as clamping rings or chains. For larger pipe diameters, process flanges in accordance with DIN EN 1092-1 (Form B1) are required to ensure a secure installation.

In addition, support feet can be used to stbailize the pipe system on the test bench. A storage and transport case is also available upon request. 

Thanks to the ExactSonic P's modular design, customizations can be made to meet specific requirements across various industries, whether for small or large pipe diameters. 

Benefits & Applications - Why the ExactSonic P is ideal for Test Benches

Advantages of ultrasonic flow measurement

  • Wear-free measurement: with no moving parts, there is no mechanical wear
  • Low pressure loss: minimal pressure drop due to no cross section blockage
  • High dynamic and wide measuring range: perfect for rapid changes in flow velocity
  • Independence from medium properties: insensitive to changes in the medium's electrical conductivity and viscosity
  • Low-maintenance and robust: very low maintenance requirements due to the absence of mechanical parts
  • Fast measurement response: modern DSP technology (digital signal processing) ensures quick data processing
  • Bidirectional measurement: Allows measurement in both directions of flow, even under changing flow conditions
  • Optimal solution for test benches: beneficial for applications requiring fast response times and high precision

Typical applications

  • Engine and turbine test benches: measurement of air/gas intake flows in test benches for engines, filters, turbochargers, HVAC systems, valves and similar applications
  • Power plants and energy facilities: monitoring of heating gas or combustion processes
  • Process and chemical plants: monitoring of gas flows, particularly under dynamic load changes
  • Research and development: calibration and comparison setups
  • Compressed air systems and supply systems: where precise flow measurements and fast response times are required

 

 

 

The ExactSonic P is particularly well-suited for applications that require a wide dynamic range and quick response times - typical requirements in test bench systems. 

Technical Specifications & Design of the test bench flow meter

Mechanical structure & assembly

Electronics & signal processing

Limits of use / Restrictions

The ExactSonic P is housed in a compact enclosure with an integrated transducer. The pipe sections can be mounted using conical or intermediate flanges. For larger pipe diameters, process flanges in accordance with DIN EN 1092-1 (Form B1) are used to ensure a secure and stable installation.

Installation is flexible and can be performed, for example using clamping rings or chains. For increased stability on the test bench, the pipe system can be equipped with support feet. For portable use or for calibration returns, the system is also available with an optional carrying case.

The ExactSonic P's integrated transducer uses digital signal processors (DSPs) that quickly and reliably analyze the transit times and differences in the ultrasonic waves. A special modulation technique ensures high resistance against interference and allows measurements even under difficult conditions.

The measured data is processed together with pressure and temperature values to precisely calculate the standard volumetric flow rate or mass flow rate.

The Exactsonic P offers both analog outputs (4-20 mA, 0-10 V) and digital interfaces such as LAN, USB and AK protocol for data transmission and parameterization.

The Exactsonic P is specifically designed for measuring clean, single-phase, neutral gases. Corrosive, multiphase or heavily contaminated gases can affect measurement accuracy.  The perimissible pressure is approximately 0.4 MPa (4 bar). For  applications requiring higher pressures or more aggressive media, the ExactFlow II model is recommended.

In environments with highly variable process conditions - such as measurements under extreme temperature fluctuations or with media containing a high proportion of solids or liquids - additional measuring methods are advisable.

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Measuring range

±1 … ±6360 m³/h
±1,2 … ±7630 kg/h

Measurement accuracy / Repeatability

<1% of actual value; <±0.5% of actual value
ISO17025 calibration

Pressure resistance

4 bar g / 0.4 MPa

Media temperature

-20 … +60 °C

Displayed indicators

Temperature, pressure, operating volume, standard volume or mass flow + option rh (gas humidity)

IP protection type

IP65

Sensor output

Analog output 4 - 20 mA and 0-10 V, updating and averaging adjustable
LAN, Ethernet RJ45, AK protocol
USB interface for log files and administration

Ultrasonic Flowmeter - U433 Operating instruction ExactSonic P - U447