FluidInsight – Fluid Contaminant Monitoring Device
Background
FluidInsight developed an innovative sensing technology capable of detecting contamination and monitoring property changes in a diverse range of fluids, from drinking water to industrial oils. Their sensor’s inline, real-time analysis provided valuable insights into fluid health, making it applicable across industries, from water quality to heavy machinery maintenance. However, their prototype was both difficult and costly to produce, limiting scalability.
The Challenge
When I first joined the project as a consulting mechanical engineer, FluidInsight’s sensor design was in a tubular format that presented several sealing and installation challenges. High-pressure, hot fluids created complexities in sealing, especially around wiring. Additionally, the design proved challenging to mount within industrial environments and secure within fluid lines.
Solution
I re-engineered the sensor’s design, transitioning from a tubular shape to a compact, modular block format. This redesign enabled a straightforward mounting system, simplified fluid connections, and had separable electrical connections at the sensing head, providing the means to remove the sensor head without affecting its fluid seal. This ultimately allowed the sensor head to be replaced independently of the rest of the circuitry, improving long-term serviceability and development capability.
Impact
Beyond the design, my role extended to supporting FluidInsight’s team as they navigated testing methodologies, fabrication processes, and the certification requirements needed for their application. From troubleshooting test failures to implementing feedback from the certification inspector, I provided technical guidance to ensure the device met compliance standards and became more cost-effective to produce.
Current Status
FluidInsight’s newly redesigned sensor is now in field testing across multiple sectors, including oil sands operations actively monitoring naphtha/bitumen ratios, as well as in heavy equipment and drinking water applications. The device’s modularity and compact form ensure future-proofing for further development as FluidInsight continues to expand its product capabilities.
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