DESC:FORM 2

THE PATENTS ACT 1970
(Act 39 of 70)
&
The Patent Rules, 2003

COMPLETE SPECIFICATION

(See Section 10 and rule 13)

TITLE OF INVENTION:

AN IOT DEVICE AND A SYSTEM FOR MONITORING PHYSICAL PROPERTIES OF FLUIDS IN REAL-TIME

APPLICANT:

1. (A) Name: XYMA Analytics Private Limited
(B) Nationality: India
(C) Address: B4-01, 4th Floor, B Block, IITM Research Park,
Kanagam, Tharamani, Chennai,
Tamil Nadu 600113

The following specification particularly describes the invention and the
manner in which it is to be performed.

TECHNICAL FIELD
[0001] The present disclosure generally relates to measurement of fluid properties, and more particularly, relates to a device and a system for In-situ / real-time measurement of multiple fluid properties and asset integrity using an IoT-enabled ultrasonic unit.
BACKGROUND
[0002] The main problem faced by industries is the in-situ simultaneous measurement of multiple fluid properties such as viscosity, density and temperature, homogeneity (fluid mixture) and metal loss in asset due to corrosion, and other stress on the material during operation. Currently rheology measurement requires blend ports to take the sample of the fluid and intrusive sensors are required to measure the fluid properties such as viscosity and density of the Newtonian and Non-Newtonian fluids. Hence real-time continuous monitoring of fluid properties of these fluids (e.g.: resin, paints, lubrication oil etc.) during production and in operation is a major challenge for industries.
[0003] Another problem is the portability of the sensor, durability, and efficiency of sensor in corrosive/hazardous/hostile environments. Any damage in the sensor leads to complete replacement of the product and directly affects the asset integrity and end product quality and leads to downtime, Also, any degradation in the fluid quality will also affect the end application such as lubrication in engine oils and paint quality during coating of metallic structures etc.
[0004] Conventional sensors like viscometer and density meters are used to measure the fluid properties such as viscosity and density of the Newtonian and Non-Newtonian fluids and specific sensors like TAN DELTA(TDN) sensors are used for oil degradation, quality monitoring, but most of these sensors are single point and single parameter measurement. These sensors have a limitation in the zone of measurement and measurement of fluid properties may get affected at high temperatures. Thus, most of these sensors can’t be exposed for high temperature application and sensor can’t be customized for integration with the asset. Human expertise is required to do the calibration and testing of the samples using conventional instruments (e.g.: viscometer).
SUMMARY
[0005] In an aspect of the present disclosure, an IOT device for monitoring physical properties of fluids in real-time during a process is disclosed. The IOT device comprises a housing comprising a solid block, at least one fluid column having a conduit integrally positioned on at least one point of the housing in the solid block, a plurality of ultrasonic transducers positioned on at least one side of the fluid column, and an IOT enabled electronic unit integrally positioned in the housing and connected to a central server through a wireless communication network, and the IOT enabled electronic unit is communicably connected the plurality of ultrasonic transducers. The plurality of ultrasonic transducers transmits ultrasonic waves passing through the fluid at one side of the fluid column, and receives the reflected ultrasonic waves passed through the fluid at the other side of the fluid column, and a plurality of physical properties of fluid in real-time during a process are measured by the plurality of ultrasonic transducers and measured properties of fluids are wirelessly transmitted to a central server by the IOT enabled electronic unit.
[0006] In another aspect of the present disclosure, a system for monitoring physical properties of fluids in real-time during a process is disclosed. The system comprises an IOT device comprising a housing comprising a solid block, at least one fluid column having a conduit integrally positioned on at least one point of the housing in the solid block, a plurality of ultrasonic transducers positioned on at least one side of the fluid column, and an IOT enabled electronic unit integrally positioned in the housing and the IOT enabled electronic unit is communicably connected the plurality of ultrasonic transducers. The system further comprises a central server communicably connected to the IOT enabled electronic unit of the IOT device through a wireless communication network, an intelligent decision unit based on Artificial intelligence and Machine learning system positioned at a remote location communicably connected to the central server through the wireless communication network, and a user communication device communicably connected to the intelligent decision unit through the wireless communication network, and the user communication device receives at least one of an alert, predictions, and corrective actions for the anomaly in the fluid.
[0007] In another aspect of the present disclosure, a device for non-invasive measurement of fluid film thickness and multiple properties of fluid in a process during real-time is disclosed. The present system provides real time measurement values that help industries to make critical decisions and control damages. The sensors system of the present invention measures fluid properties such as viscosity, density, temperature, and asset integrity simultaneously using single electronics unit and with using a single or multiple ultrasonic longitudinal and/or shear transducer.

BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The specification refers to the following appended figures, in which the use of like reference numerals in different figures is intended to illustrate like or analogous components.
[0009] Figure 1 illustrates a schematic of an IOT device for non-invasive measurement of physical properties of fluid in real-time during a process in accordance with an embodiment of the present disclosure.
[0010] Figure 2 illustrates a schematic of an IOT device for non-invasive measurement of physical properties of fluid in real-time during a process in accordance with another embodiment of the present disclosure.
[0011] Figure 3 illustrates a schematic of an IOT device for non-invasive measurement of physical properties of fluid in real-time during a process in accordance with another embodiment of the present disclosure.
[0012] Figures 4 - 5 illustrate isometric view of an IOT device and a top view of the IOT device for non-invasively monitoring physical properties of fluids in real-time during a process in accordance with another embodiment of the present disclosure respectively.
[0013] Figure 6 illustrates a schematic of an IOT enabled electronic unit (160) in accordance with an embodiment of the present disclosure.
[0014] Figure 7 illustrates a system for monitoring physical properties of fluids in real-time during a process in accordance with a third embodiment of the present disclosure.
[0015] Figure 8 (a) – 8 (c) illustrate measurement results in non-Newtonian fluid in accordance with one example of the present disclosure.
[0016] Figure 9 (a) – 9 (c) illustrate measurement results in Enamel in accordance with another example of the present disclosure.
[0017] Figure 10 (a) – 10 (b) illustrate curves showing measurement results in Newtonian fluid in accordance with another example of the present disclosure.
[0018] Figure 11 illustrates a curve showing thickness measurement results in accordance with yet another example of the present disclosure.
[0019] Figure 12 illustrates an exemplary system with two IOT devices monitoring physical properties of fluids in a fluid container in real-time during a process in accordance with another example of the present disclosure.
[0020] Figure 13 illustrates a graph showing measurement of time of flight (ToF) of the ultrasonic signal at different RPM in accordance with another example of the present disclosure.
[0021] Figure 14 illustrates ultrasonic data and obtained physical properties of an oil sample with degradation in accordance with another example of the present disclosure.
[0022] Figures 15 (a) – 15 (b) illustrate curves showing the TOF of the ultrasonic signals and the amplitude of oil sample with respect to the oil degradation in accordance with another example of the present disclosure.
[0023] Figure 16 illustrates ultrasonic data and obtained physical properties of an oil sample in accordance with another example of the present disclosure.
[0024] Figures 17 (a) – 17 (b) illustrate curves showing the TOF of the ultrasonic signals and the amplitude of oil sample with respect to the oil degradation in accordance with another example of the present disclosure.
[0025] Figure 18 illustrates a table showing the TOF (TOA) of the ultrasonic signals and the amplitude of different oil samples in accordance with another example of the present disclosure.
[0026] Figure 19 (a) – 19 (b) illustrate graphs showing the amplitude and the TOF of the ultrasonic signals of different oil samples in accordance with another example of the present disclosure.

DETAILED DESCRIPTION
[0027] According to the present disclosure, a system and method for non-invasive and invasive measurement of fluid film thickness and multiple properties of fluid based on ultrasonic bulk wave technology are disclosed. The system outputs real time measurement values of fluid properties to dynamically decide on control techniques and avoid damages. There are multiple configurations in the present invention and the system is capable of simultaneously measuring properties of the liquid selected from viscosity, density, temperature, asset integrity and homogeneity. The system uses a single electronic unit and a single or multiple ultrasonic longitudinal and/or shear transducer.
[0028] In an embodiment of the present disclosure, an IoT enabled ultrasonic device is disclosed for real-time monitoring of fluid properties such as viscosity, density, asset integrity, and homogeneity of both highly viscous and non-viscous fluids and also for both Newtonian and non-Newtonian fluids.
[0029] The in-situ measurement of the properties of the fluid in the present system is based on the principle of through-transmission (TT). In TT mode two transducers are used, one transducer acts as a transmitter and the other acts as a receiver. When an ultrasonic wave passes through any fluid medium then depending upon fluid properties and the temperature, velocity of ultrasonic signal changes and hence a shift in time of flight (ToF) is captured.
[0030] In an embodiment of the present disclosure, an IOT device for monitoring physical properties of fluids in real-time during a process is disclosed. The IOT device may comprise a housing comprising a solid block, at least one fluid column having a conduit integrally positioned on at least one point of the housing in the solid block, a plurality of ultrasonic transducers positioned on at least one side of the fluid column, and an IOT enabled electronic unit integrally positioned in the housing and connected to a central server through a wireless communication network, and the IOT enabled electronic unit is communicably connected the plurality of ultrasonic transducers.
[0031] In an embodiment of the present disclosure, the plurality of ultrasonic transducers transmits ultrasonic waves passing through the fluid at one side of the fluid column, and receives the ultrasonic waves passed through the fluid at the other side of the fluid column, and a plurality of physical properties of fluid in real-time during a process are measured by the plurality of ultrasonic transducers and measured properties of fluids are wirelessly transmitted to a central server by the IOT enabled electronic unit.
[0032] In an embodiment of the present disclosure, the plurality of ultrasonic transducers comprises a plurality of ultrasonic transducers positioned at a plurality of points of the at least one fluid column on at least one side.
[0033] In another embodiment of the present disclosure, the plurality of ultrasonic transducers comprises a plurality of pairs of ultrasonic transducers positioned at both sides of the fluid column.
[0034] In another embodiment of the present disclosure, the plurality of ultrasonic transducers comprises at least one pair of longitudinal transducers positioned at both side of the fluid column at a front end of the housing; and at least one pair of shear transducers positioned at both side of the fluid column at a rear end of the housing.
[0035] In another embodiment of the present disclosure, the plurality of ultrasonic transducers comprises a pair of at least one longitudinal transducer and at least one shear transducer positioned at either side of the fluid column of the housing.
[0036] In another embodiment of the present disclosure, the solid block is made of a material selected from a metal, non-metal, and metallic alloys.

[0037] In another embodiment of the present disclosure, the solid block is made of a material selected from Aluminium, Steel, Stainless Steel, and Acrylic.
[0038] In another embodiment of the present disclosure, at least one fluid column having a conduit is integrally positioned at a center of the housing and passing through the entire length of the housing and the fluid column comprises a first flange arranged at a first end of the fluid column and a second flange arranged at a second end of the fluid column.
[0039] In an embodiment of the present disclosure, the IOT device is attached to a fluid pipe during a process for non-invasively monitoring physical properties of a fluid flowing through the pipe in real-time.
[0040] In another embodiment of the present disclosure, the IOT device is immersed into a fluid container during a process for invasively monitoring physical properties of a fluid in the container in real-time.
[0041] In another embodiment of the present disclosure, the IOT device further comprises a reflector plate integrally positioned adjacent to the fluid column of the housing.
[0042] In another embodiment of the present disclosure, a reflector plate is immersed into a fluid container and a fluid column of the housing is positioned outside the fluid container for non-invasively monitoring physical properties of the fluid in the container during a process in real-time.
[0043] In an embodiment of the present disclosure, the plurality of physical properties of the fluid are selected from viscosity, density, temperature, asset integrity and homogeneity of the fluid.
[0044] In an embodiment of the present disclosure, the fluid is selected from a group comprising viscous and non-viscous fluid, Newtonian, and Non-Newtonian fluids.
[0045] In the present invention, ultrasonic transducer is a Longitudinal transducer working at an operational frequency in a range of 0.5 MHz to 2 MHz, and the IOT enabled electronic unit sends the electric pulse to the Longitudinal transducer and signal may be received by the same unit. After capturing multiple A-scans, post processing of signals starts and results are obtained co-related with fluid properties.
[0046] Referring to Figure 1, illustrated is a schematic of an IOT device for non-invasive measurement of physical properties of fluid in real-time during a process in accordance with an embodiment of the present disclosure. The IOT device (100) comprises a solid block (115) with a fluid/liquid column (120), at least two longitudinal ultrasonic transducers (140, 145) for through-transmission mode positioned on both sides of the fluid column (120, 130), and an enclosure (110) to hold the probe/ transducers and solid block, and an IOT enabled electronic unit (160) integrally positioned in the enclosure (110) and connected to a central server (300) for sending and receiving signals through a wireless communication network (200). The IOT enabled electronic unit (160) is communicably connected the plurality of ultrasonic transducers (140, 145). The solid block is used because the ultrasonic velocity is less in solid materials and therefore the first signal does not get merged with near zone signals.
[0047] The plurality of ultrasonic transducers (140, 145) transmits ultrasonic waves passing through the fluid (170) at one side of the fluid column, and receives the reflected ultrasonic waves passed through the fluid (170) at the other side of the fluid column. The electronic unit may further process the data and generates the measurement results. The device further may comprise a display unit to display the results. Thus, a plurality of physical properties of fluid (170) in real-time during a process are measured by the plurality of ultrasonic transducers (140, 145) and measured properties of fluids are wirelessly transmitted to a central server (300) by the IOT enabled electronic unit (160). The plurality of physical properties of the fluid are selected from viscosity, density, temperature, asset integrity and homogeneity of the fluid. The fluid may be one of viscous and non-viscous fluid, Newtonian, and Non-Newtonian fluids.
[0048] In an embodiment of the present disclosure, the IOT device is used for monitoring physical properties of fluids in real-time during a process of manufacturing the fluid, for example paint, oil, polymer, resin, chemicals.
[0049] In another embodiment of the present disclosure, the solid block may be made of a material selected from Aluminium, Steel, Stainless Steel, and Acrylic.
[0050] Referring to Figure 2, illustrated is a schematic of an IOT device for non-invasive measurement of physical properties of fluid in real-time during a process in accordance with another embodiment of the present disclosure. The IOT device (100) comprises a solid block (115) with a liquid column (120), at least two longitudinal transducers (140, 145) and at least two Shear transducers (150, 155) for through-transmission mode, an enclosure (110) to hold the probe and solid block, and an IOT enabled electronic unit (160) integrally positioned in the enclosure (110) and connected to a central server (300) for sending and receiving signals through a wireless communication network (200). In the embodiment, Shear transducers (150, 155) are configured to work at an operational frequency in a range of 0.5 MHz to 2 MHz.
[0051] In one embodiment, Longitudinal transducers are used for sending signals and Shear transducers are used for receiving the signals. In another embodiment, Shear transducers are used for sending the signals and Longitudinal transducers are used for receiving the signals.
[0052] Referring to Figure 3, illustrated is a schematic of an IOT device for non-invasive measurement of physical properties of fluid in real-time during a process in accordance with another embodiment of the present disclosure. The IOT device (100) comprises a solid block (115) with a liquid column (120), a pair of longitudinal Ultrasonic transducers (140, 145) and a pair of Shear transducers (150, 155) for through-transmission mode, an enclosure/housing (110) to hold the probe and solid block, and an IOT enabled electronic unit (160) for sending and receiving signals. In the embodiment of the present invention, a pair of Longitudinal (L-transducer) may be attached in through transmission mode. The pair of Longitudinal configurations may be used at multiple points to monitor the asset and measure the fluid properties at different locations.
[0053] Referring to Figures 4 - 5, illustrated are an isometric view of an IOT device and a top view of the IOT device for non-invasively monitoring physical properties of fluids in real-time during a process in accordance with another embodiment of the present disclosure respectively. The IOT device (1000) comprises a housing (1100) comprising a solid block (1150), a fluid column (1200) having a conduit (1250) integrally positioned at a center of the housing and passing through the entire length of the housing (1100). The IOT device (1000) further comprises a sensor assembly having a plurality of ultrasonic transducers (140, 145, 150, 155) positioned on both sides of the fluid column (1200). The plurality of ultrasonic transducers (140, 145, 150, 155) may be positioned on both left side and right side of the fluid column (1200). The plurality of ultrasonic transducers (140, 145, 150, 155) may be positioned on both sides of the fluid column (1200) at a front end and a rear end of the housing (1100). The IOT device (1000) further comprises an IOT enabled electronic unit (160) integrally positioned in the housing (110) as similar to previous embodiments and connected to a central server (300) through a wireless communication network (200), and the IOT enabled electronic unit (160) is communicably connected the plurality of ultrasonic transducers (140, 145, 150, 155);
[0054] In Figure 4-5, the IOT device (1000) comprises comprises a first flange (1270) arranged at a first end (1220) of the fluid column (1200) and a second flange (1280) arranged at a second end (1240) of the fluid column (1200). The flanges are configured so that the flow meter can be connected to an external pipe during a process for non-invasively monitoring physical properties of a fluid flowing through the pipe in real-time. Each flange comprises a plurality of bolt holes (1290) with an internal diameter. The IOT device (1000) further may comprise contactors / connections outside the housing for inputting and outputting signals when required.
[0055] Referring to Figure 6, illustrated is a schematic of an IOT enabled electronic unit (160) in accordance with an embodiment of the present disclosure. The IOT enabled electronic unit (160) comprises a multi-channel receiver (162) communicably connected to the plurality of ultrasonic transducers (140, 145, 150, 155), a data acquisition and computational unit (164) communicably connected to the multi-channel receiver (162), and a data transferring unit (166) communicably connected to the data acquisition and computational unit (164). The multi-channel receiver (162) receives measured analog signals for physical properties of fluids, particularly from transmission and receipt of signals from ultrasonic waves from transducers. The data acquisition and computational unit (164) receives analog signals of the plurality of ultrasonic transducers (140, 145, 150, 155) from multi-channel receiver (162). The data acquisition and computational unit (164) further converts analog signals into digital signals. Further, the unit (164) analyzes digtital signals and monitors properties of fluid for detecting an anomaly. The data transferring unit (166) may comprise a wireless communication module (166a) communicably connected to the central server (300) through the wireless communication network (200) and transfers the digital signals from the data acquisition and computational unit (164) to the central server (200).
[0056] In an embodiment of the present disclosure, the wireless communication network may be not only limited to a Radio Frequency (RF), Frequency-Division Multiplexing (FDM), Orthogonal FDM (OFDM), Single Carrier Frequency Division Multiple Access (SC-FDMA), Time-Division Multiplexing (TDM), Time-Division Multiple Access (TDMA), Extended TDMA (E-TDMA), General Packet Radio Service (GPRS), extended GPRS, Code-Division Multiple Access (CDMA), Wideband CDMA (WCDMA), CDMA 2000, single-carrier CDMA, multi-carrier CDMA, Multi-Carrier Modulation (MDM), Discrete Multi-Tone (DMT), Bluetooth®, Global Positioning System (GPS), Wireless Fidelity (Wi-Fi), Wi-Max, ZigBee™, Ultra-Wideband (UWB), Global System for Mobile communication (GSM), second generation (2G), 2.5G, 3G, 3.5G, 4G, 4.5G, Fifth Generation (5G) mobile networks, Sixth Generation (6G) mobile networks, 3GPP, Long Term Evolution (LTE) cellular system, LTE advance cellular system, LTE Unlicensed systems, High-Speed Downlink Packet Access (HSDPA), High-Speed Uplink Packet Access (HSUPA), High-Speed Packet Access (HSPA), HSPA+, Single Carrier Radio Transmission Technology (1XRTT), Evolution-Data Optimized (EV-DO), Enhanced Data rates for GSM Evolution (EDGE), and the like.
[0057] Referring to Figure 7, illustrated is a system for monitoring physical properties of fluids in real-time during a process in accordance with a third embodiment of the present disclosure. The system comprises an IOT device used similar to the discussed in previous embodiments. The system further comprise a central server (300) communicably connected to the IOT enabled electronic unit (160) of the IOT device through a wireless communication network (200), an intelligent decision unit (400) positioned at a remote location and communicably connected to the central server (300) through the wireless communication network (200), and a user communication device (500) communicably connected to the intelligent decision unit (400) through the wireless communication network (200). The central server may be a remote server running in a computing device.
[0058] The intelligent decision unit (400) is an embedded with Artificial intelligence and Machine learning powered system leverages user input and historical data of fluids and transducers to detect an anomaly in the fluid and generate at least one of an alert, predictions, and corrective actions for the anomaly in the fluid. The user communication device (500) may comprise a graphical user interface for receiving and displaying at least one of an alert, predictions, and corrective actions for the anomaly in the fluid from the intelligent decision unit (400).
[0059] In an embodiment, the user communication device (500) is installed with a proprietary software for monitoring physical properties of fluids in real-time during a process of manufacturing. The measured properties of fluid along with one of the alert, predictions, and corrective actions for the anomaly in the fluid may be displayed in real-time and the user may take appropriate corrective actions for efficient manufacturing processes in industries such as: Paint, oil, polymer, resin, chemicals.
[0060] Referring to Figure 8 (a) – 8 (c), illustrated are measurement results in non-Newtonian fluid in accordance with one example of the present disclosure. Figure 8 (a) shows curve represents the change in time of flight of Longitudinal through transmission mode with respect to change in viscosity. Figure 8 (b) shows curve represents the change in amplitude with respect to various sample points in accordance with another example of the present disclosure. Figure 8 (c) shows viscosity of fluid at the start and end of the experiment taken by Brookfield viscometer using Spindle-18 in a tabular format.
[0061] Referring to Figure 9 (a) – 9 (c), illustrated are measurement results in Enamel in accordance with another example of the present disclosure. Figure 9 (a) shows the variation in time of flight with respect to different temperatures. This signal has been taken in through transmission mode. Figure 9 (b) shows enlarged view of the curve between the time 40 – 50 µsec of Figure 9 (a). Figure 9 (c) shows variation in viscosity of enamel with respect to temperature in a tabular format.
[0062] Referring to Figure 10 (a) – 10 (b), illustrated are curves showing measurement results in Newtonian fluid in accordance with another example of the present disclosure. Figure 10 (a) – 10 (b) show the variation in time of flight and amplitude with respect to fluid properties of samples A & B. Figure 10 (a) shows the curve representing the change in time of flight of Longitudinal wave through transmission mode. Figure 10 (b) shows curve representing the change in time of flight of two different configuration of L&S transducers in Sample A.
[0063] Referring to Figure 11, illustrated is a curve showing thickness measurement results in accordance with yet another example of the present disclosure. In this example, thickness of 1mm MAK MP GREASE 3 grade has applied on solid block and then signal has been captured for the analysis. Figure 11 shows the comparison of results obtained with the 1 mm coating of MP GREASE 3 grade and without coating.
[0064] To validate the present system, experiments were performed using the present IOT device for various fluids and various properties and the homogeneity of fluid was observed in real-time during the process. Referring to Figure 12, illustrates an exemplary system with two IOT devices monitoring physical properties of fluids in a fluid container in real-time during a process in accordance with another example of the present disclosure. The two IOT devices comprises two different setups, namely Setup S1 and Setup S2. The Setup S1 comprises a housing and a fluid column having a conduit integrally positioned at a point of the housing and extending away from the housing for measurement and monitoring of properties of fluids. The Setup S1 comprises a plurality of ultrasonic transducers position at a plurality of points of the fluid column. The transducers may be positioned on either one side or both side of the fluid column. As shown in Figure 12, the plurality of ultrasonic transducers were positioned at multiple locations of the column for transmitting longitudinal wavemode at multiple locations in the system. The transmitted signals were captured in a pulse echo mode. The setup S1 also has a reflector plate (132) placed at a particular distance adjacent to the liquid column and the ultrasonic transducers. The reflector plate and the fluid column are immersed in the fluid container and the physical properties of the fluid in the container are invasively monitored during a process in real-time.
[0065] In another embodiment, the IOT setup S1 further comprises a reflector plate (132) integrally positioned adjacent to the fluid column of the housing. The reflector plate is immersed into a fluid container and the fluid column (120) with multi-point transducers is positioned outside the fluid container for non-invasively monitoring physical properties of the fluid in the container during a process in real-time. The reflector plate can also be used as multi-point temperature sensor system for monitoring temperatures of fluid in real-time.
[0066] The Setup S2 comprises a housing and two fluid columns (120, 130) positioned adjacent to each other in the housing and extending away from the housing for measurement and monitoring of properties of fluids. The plurality of ultrasonic transducers position at a plurality of points of both fluid columns. The plurality of ultrasonic transducers were positioned at multiple locations of the column for transmitting longitudinal wavemode at multiple locations in the system. The transmitted signals were captured in a pulse catch mode. The ultrasonic wave velocity and transmission coefficient of a fluid is a function of its composition and quality. A change in composition or quality is sensed by the change in the transit time and the transmitted energy of the ultrasonic sound wave. The ultrasonic transducers of S1 and S2, may be designed as a separate IOT device as shown in Figure 4-5 and attached to an external pipe for measuring the oil degradation.
[0067] Experiments were carried out in a container with a non-Newtonian fluid to understand the homogeneity of the fluid using the setup S1. A paint/polymer/resin like substance is used as a fluid medium, here the time of flight of the signal from the reflector plate is used as a reference to find the fluid quality (homogeneity) of the sample. The ultrasonic transducers were set to operate at a frequency of 2MHz. Experiments were carried out at different RPM in the mixer, a shift in time of flight (ToF) of the ultrasonic signal was captured, and the obtained results are shown in figure 13.
[0068] Referring to Figure 13, illustrated is a graph showing measurement of time of flight (ToF) of the ultrasonic signal at different RPM in accordance with another example of the present disclosure. From the Figure 13, it was observed that at lower rpm the fluid is close to static in the area of observation. So, the fluid property is also not changing due to which the time of reflection is almost constant. As the rpm is increasing, fluid motion is more in the area of interest and all the settled paint will get mixed thoroughly which causes increase in viscosity and thereby increase in Time of Reflection.
[0069] Similar to the above, experiments were carried out using different paint samples like emulsion and enamel and their respective mixture and their viscosity and the calibration equation based on ultrasonic data (ToF).
[0070] Experiments were carried out using the IOT setup S2 and two fluids with different fluid viscosity were used to simulate the oil degradation experiments. Two fluids involve fresh 5W30 as OIL A and used 5W30 as OIL B in the experiments. Figure 14 illustrates ultrasonic data and obtained physical properties of an oil sample with degradation in accordance with another example of the present disclosure. The oil sample and their corresponding viscosity, density and the ultrasonic data obtained for that particular fluid property is shown in Figure 14. Figures 15 (a) – 15 (b) illustrate curves showing the TOF of the ultrasonic signals and the amplitude of oil sample with respect to the oil degradation in accordance with another example of the present disclosure.
[0071] Further, Experiments were carried out using the IOT setup S2 and another two fluids with different fluid viscosity were used to simulate the oil degradation experiments. These two fluids involve System68 as OIL A and used Prime46 as OIL B in the experiments. Figure 16 illustrates ultrasonic data and obtained physical properties of an oil sample in accordance with another example of the present disclosure. The oil sample and their corresponding viscosity, density and the ultrasonic data obtained for that particular fluid property is shown in Figure 16. Figures 17 (a) – 17 (b) illustrate curves showing the TOF of the ultrasonic signals and the amplitude of oil sample with respect to the oil degradation in accordance with another example of the present disclosure.
[0072] Similarly, experiments were carried out using different oil samples and their respective mixture and their viscosity and the calibration equation based on ultrasonic data (ToF) was derived. To validate the sensor setups of IOT device, sensitivity study was conducted. Figure 18 illustrates a table showing the TOF (TOA) of the ultrasonic signals and the amplitude of different oil samples in accordance with another example of the present disclosure. The same has been illustrated as graphs in Figures 19 (a) – 19 (b). Figure 19 (a) – 19 (b) illustrate graphs showing the amplitude and the TOF of the ultrasonic signals of different oil samples in accordance with another example of the present disclosure. The IOT Device of the present invention was able to clearly able to distinguish different fluid and their mixture by tracking the amplitude and the TOF of the ultrasonic signals.
[0073] In the present invention, a SINGLE ULTRASONIC SENSOR UNIT with reflector plate in pulse echo mode as setup S1 and TWO ULTRASONIC SENSOR UNIT in pulse catch mode as setup S2 can be designed to measure the fluid properties of both Newtonian and non-Newtonian fluid. The change in TOF of S1 is used to monitor the HOMOGENEITY OF paint samples and the change in TOF of S2 is used to monitor the FLUID PROPERTIES OF both Newtonian and non-Newtonian fluid (oil, paint).
[0074] The present invention is used to the industry to measure Realtime fluid properties such as viscosity and homogeneity of both viscous and non-viscous fluid and its distributed temperature profile in Realtime. Since the sensors are easy to install and IoT enabled, and the system is able to generate the data frequency of one minute or per second and any corrective action in Realtime to be taken can be incorporated easily during the process. The present invention helps in early detection of fluids during a process and thus helps industries to achieve their SDG goals like, energy saving and avoid process rejection and increase the asset life of the fluids.
,CLAIMS:We Claim:

1. An IOT device (100) for monitoring physical properties of fluids in real-time during a process, comprising:
a housing (110) comprising a solid block (115);
at least one fluid column (120, 130) having a conduit integrally positioned on at least one point of the housing (110) in the solid block (115);
a plurality of ultrasonic transducers (140, 145, 150, 155) positioned on at least one side of the fluid column (120, 130); and
an IOT enabled electronic unit (160) integrally positioned in the housing (110) and connected to a central server (300) through a wireless communication network (200), and the IOT enabled electronic unit (160) is communicably connected the plurality of ultrasonic transducers (140, 145, 150, 155);
wherein the plurality of ultrasonic transducers (140, 145, 150, 155) transmits ultrasonic waves passing through the fluid (170) at one side of the fluid column, and receives the ultrasonic waves passed through the fluid (170) at the other side of the fluid column, and a plurality of physical properties of fluid (170) in real-time during a process are measured by the plurality of ultrasonic transducers (140, 145, 150, 155) and measured properties of fluids are wirelessly transmitted to a central server (300) by the IOT enabled electronic unit (160).
2. The IOT device as claimed in claim 1, wherein the plurality of ultrasonic transducers (140, 145, 150, 155) have an operational frequency in a range of 0.5 MHz to 2 MHz and comprises a plurality of ultrasonic transducers (140, 145, 150, 155) positioned at a plurality of points of the at least one fluid column (120, 130) on at least one side.
3. The IOT device as claimed in claim 1, wherein the plurality of ultrasonic transducers (140, 145, 150, 155) comprises a plurality of pairs ((140, 145), (150, 155)) of ultrasonic transducers positioned at both sides of the fluid column (120, 130).
4. The IOT device as claimed in claim 1, wherein the plurality of ultrasonic transducers (140, 145, 150, 155) comprises:
at least one pair of longitudinal transducers (140, 145) positioned at both side of the fluid column at a front end (115) of the housing (110); and
at least one pair of shear transducers (150, 155) positioned at both side of the fluid column at a rear end (118) of the housing (110).
5. The IOT device as claimed in claim 1, wherein the plurality of ultrasonic transducers (140, 145, 150, 155) comprises:
a pair of at least one longitudinal transducer (140, 145) and at least one shear transducer positioned (150, 155) at either side of the fluid column (120, 130) of the housing (110).
6. The IOT device as claimed in claim 1, wherein at least one fluid column (1200) having a conduit (1250) is integrally positioned at a center of the housing and passing through the entire length of the housing (1100) and the IOT device comprises a first flange (1270) arranged at a first end (1220) of the fluid column (1200) and a second flange (1280) arranged at a second end (1240) of the fluid column (1200).
7. The IOT device as claimed in claim 1, wherein the IOT device (100) is attached to a fluid pipe during a process for non-invasively monitoring physical properties of a fluid flowing through the pipe in real-time.
8. The IOT device as claimed in claim 1, wherein the IOT device (100) is immersed into a fluid container (200) during a process for invasively monitoring physical properties of a fluid in the container in real-time.
9. The IOT device as claimed in claim 1, wherein the IOT device (100) further comprises a reflector plate (132) integrally positioned adjacent to the fluid column (120) of the housing.
10. The IOT device as claimed in claim 9, wherein the reflector plate (132) is immersed into a fluid container (200) and fluid column (120) of the housing is positioned outside the fluid container (200) for non-invasively monitoring physical properties of the fluid in the container (200) during a process in real-time.
11. The IOT device as claimed in claim 1, wherein the IOT enabled electronic unit (160) comprises:
a multi-channel receiver (162) communicably connected to the plurality of ultrasonic transducers (140, 145, 150, 155) for receiving analog signals of measurement of fluids from ultrasonic transducers;
a data acquisition and computational unit (164) communicably connected to the multi-channel receiver (162), wherein the data acquisition and computational unit (164) converts analog signals received from the plurality of ultrasonic transducers (140, 145, 150, 155) into digital signals and analyzes and monitors properties of fluid for anomaly; and
a data transferring unit (166) communicably connected to the data acquisition and computational unit (164), wherein the data transferring unit (166) comprises a wireless communication module (166a) communicably connected to the central server (300) through the wireless communication network (200) and transfers the digital signals from the data acquisition and computational unit (164) to the central server (200).
12. The IOT device as claimed in claim 1, wherein the plurality of physical properties of the fluid are selected from viscosity, density, temperature, asset integrity and homogeneity of the fluid.
13. The IOT device as claimed in claim 1, wherein fluid is selected from a group comprising viscous and non-viscous fluid, Newtonian, and Non-Newtonian fluids.
14. A system for monitoring physical properties of fluids in real-time during a process, comprising:
an IOT device (100) comprising:
a housing (110) comprising a solid block (115);
at least one fluid column (120, 130) having a conduit integrally positioned on at least one point of the housing (110) in the solid block (115);
a plurality of ultrasonic transducers (140, 145, 150, 155) positioned on at least one side of the fluid column (120, 130); and
an IOT enabled electronic unit (160) integrally positioned in the housing (110), and the IOT enabled electronic unit (160) is communicably connected the plurality of pairs of ultrasonic transducers (140, 145, 150, 155).
a central server (300) communicably connected to the IOT enabled electronic unit (160) of the IOT device through a wireless communication network (200);
an intelligent decision unit (400) based on Artificial intelligence and Machine learning system positioned at a remote location communicably connected to the central server (300) through the wireless communication network (200); and
a user communication device (500) communicably connected to the intelligent decision unit (400) through the wireless communication network (200), and the user communication device (500) receives at least one of an alert, predictions, and corrective actions for the anomaly in the fluid.