Acoustic and optical sensing configurations for bulk solids mass flow measurements

The emergence of trends such as the Industrial Internet of Things (IIOT), Industry 4.0 and Process analytical technology has heightened the demand for real-time, in-line and affordable sensors. The mass flow rate of bulk solids is a parameter that is invaluable to process understanding in many applications. Despite this the availability of affordable sensors is limited. This paper will investigate some novel methods sensing arrangements utilising cost-effective components including optical and acoustic sensors techniques with a comparison of these methods against a commercial sensor for their evaluation. Experimental results demonstrate that reliable monitoring of powder flow parameters is achieved and that the system is able to track fluctuations of powder flow in pipes in both freefall and pneumatic conveyance applications.