Ultrasonic water meter base plate and welding auxiliary tool

Abstract

The application discloses an ultrasonic water meter base plate, which comprises a main water channel formed by a meter shell, and further comprises an ultrasonic transducer, a reflecting device, a transducer support for mounting the ultrasonic transducer and the reflecting device, a transducer support fixing boss for connecting the meter shell and the transducer support, and an ultrasonic reflection channel arranged in the transducer support fixing boss, wherein the center axes of the two ultrasonic reflection channels coincide and intersect with the center axis of the main water channel, and the intersecting angle is less than 90 degrees; and the application further discloses a welding auxiliary tool. Since the ultrasonic transducer and the reflecting device are both mounted on the transducer support, the ultrasonic reflection channel is not occupied, the cross-sectional radius of the ultrasonic reflection channel can be reduced as much as possible, the influence on the water flow channel is reduced, the interference sources such as vortex and cavitation affecting ultrasonic measurement are reduced, the software algorithm is simple, the measurement is accurate, and the requirement on the transducer is reduced.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic water meters, and in particular to a small-diameter ultrasonic water meter base and its molding method that does not change the water flow pattern. Background Technology

[0002] Ultrasonic water meters measure flow velocity using the ultrasonic time-difference principle. This involves detecting the time difference caused by the change in speed as the ultrasonic beam propagates upstream and downstream in water, analyzing the data to determine the water velocity, and then calculating the flow rate. Compared to mechanical water meters, ultrasonic water meters offer advantages such as high accuracy, high reliability, wide range capability, long service life, no moving parts, no parameter settings required, installation at any angle, and extended lifespan. Because they acquire data electronically, additional functions such as calculation, analysis, and remote transmission are easier to implement. They also offer comprehensive communication capabilities, meeting various communication and wireless networking requirements. This addresses many issues of traditional water meters, making them more suitable for tiered water pricing and promoting water conservation and rational utilization.

[0003] Ultrasonic water meters require high manufacturing precision, especially small-diameter ultrasonic water meters. Due to their small casing size, ultrasonic channels are added to the meter casing at the expense of water flow patterns and ultrasonic transmission distance, further increasing the difficulty of manufacturing and improving meter accuracy. Regardless of whether ultrasonic signal transmission is through-beam or reflection, the velocity of sound waves in the water flow is affected by factors such as velocity distortion and swirling currents.

[0004] In the prior art, for example, the "An Ultrasonic Water Meter" disclosed in Chinese patent document CN110455360B includes an inlet section, an outlet section, and a measuring section. One end of the measuring section is equipped with an ultrasonic generator, and the other end with an ultrasonic receiver. While increasing the transmission distance by using an angled ultrasonic measuring channel reduces the impact of the measuring device on the water flow, and reducing the structural size of the ultrasonic wave by transmitting it only once, its drawback is that because the ultrasonic wave is only transmitted once to reduce the structural size, it is impossible to analyze and determine the water flow rate by transmitting it twice and correcting for the time difference caused by the speed change during upstream and downstream propagation, thus sacrificing accuracy. Summary of the Invention

[0005] To overcome the problem that existing ultrasonic water meters sacrifice accuracy in order to reduce the size of the ultrasonic transceiver, the present invention provides an ultrasonic water meter base with high accuracy and suitable for small diameters.

[0006] A further objective of this invention is to improve measurement accuracy by mounting both the ultrasonic transducer and the reflection device on the transducer bracket, thus avoiding the obstruction of the ultrasonic reflection channel and reducing the impact on the water flow channel.

[0007] This invention is achieved through the following technical solution: an ultrasonic water meter base, comprising a main water channel formed by the meter casing, and further comprising:

[0008] Ultrasonic transducers are used to receive and transmit ultrasonic waves.

[0009] A reflector, used to reflect ultrasonic waves emitted by an ultrasonic transducer;

[0010] A transducer bracket is installed at the entrance of the ultrasonic reflection channel away from the main waterway, and is used to install an ultrasonic transducer and a reflection device. A transducer bracket fixing boss is used to connect the casing and the transducer bracket. Two transducer bracket fixing bosses are provided. Each transducer bracket fixing boss has an ultrasonic reflection channel inside. The central axes of the two ultrasonic reflection channels coincide and intersect with the central axis of the main waterway, and the angle of intersection is less than 90°.

[0011] In use, after the ultrasonic transducer on one side emits ultrasonic waves, the waves are reflected by the reflector and enter the ultrasonic reflection channel. Then, after being reflected by the reflector on the other side, the waves are received by the ultrasonic transducer on the other side. The ultrasonic transducer on the other side then emits ultrasonic waves, which enter the ultrasonic transducer on the opposite side through the opposite path. This allows the detection of the time difference caused by the change in speed when the ultrasonic beam propagates in the water upstream and downstream. The analysis and processing are then used to obtain the water flow rate and further calculate the water flow rate.

[0012] Since both the ultrasonic transducer and the reflector are mounted on the transducer bracket, they do not occupy the ultrasonic reflection channel. This allows the cross-sectional radius of the ultrasonic reflection channel to be minimized, thereby reducing the impact on the water flow channel and minimizing interference sources such as eddies and cavitation that affect ultrasonic measurement. The software algorithm is simple and the measurement is accurate. By calculating the flow velocity through the ultrasonic paths on both the upstream and downstream sides, the transmission line length is increased, improving measurement accuracy and reducing the requirements for the transducer.

[0013] Preferably, the reflecting device includes a reflecting column, the upper end of which is a reflecting surface, and the lower end of which is interference-fitted onto a transducer bracket.

[0014] The lower end of the columnar reflector is easy to install, and the angle of the reflective surface above the reflective column can be easily adjusted for installation and testing.

[0015] Preferably, the watch case is also provided with a temperature sensing boss and a reserved sensor boss.

[0016] The temperature sensing boss is used to install a temperature sensor to measure the temperature of the flowing water; the reserved sensor boss can easily install pressure sensors, ambient temperature sensors and water quality sensors, and can be expanded with instruments and functions as needed, so as to achieve the goal of monitoring multiple parameters with one water meter.

[0017] Preferably, the casing also includes an acceleration pipe with a variable diameter section and ultrasonic vias at corresponding positions in the ultrasonic reflection channel. The acceleration pipe increases the water flow velocity, thereby reducing the sensitivity of the flow velocity measurement equipment and lowering the accuracy requirements for measuring equipment such as ultrasonic transducers.

[0018] Preferably, the temperature sensing boss, the reserved sensor boss, the housing and the transducer bracket fixing boss are integrally molded, including casting and die casting, which improves production efficiency and reduces installation steps.

[0019] Preferably, the transducer bracket fixing boss is welded to the watch case, and the transducer bracket is welded to the transducer bracket fixing boss. When the watch case is manufactured using a material that is difficult to form in one piece, it is installed by welding.

[0020] Preferably, the temperature sensing boss and the reserved sensor boss are welded to the watch case. When the watch case is manufactured using a material that is difficult to form in one piece, it is installed by welding.

[0021] Preferably, it also includes a circuit board box, which contains circuit board box components for functions such as signal transmission, power supply, and ultrasonic calculation.

[0022] A welding auxiliary tooling is used to ensure that the central axes of two ultrasonic reflection channels coincide when welding the base of an ultrasonic water meter. It includes positioning sections for inserting into the ultrasonic reflection channels at both ends, and several connecting sections that are hinged to each other for hinged to the two positioning sections. The number of connecting sections is at least two, and the hinge axes of the hinges are in the same direction.

[0023] Before welding, place the watch case horizontally. Straighten the welding auxiliary tooling and insert it into the reserved opening on the watch case for installing the transducer bracket fixing boss until it passes through the reserved opening on the other side, with the positioning section exposed outside the watch case. Keep the welding auxiliary tooling horizontal and ensure that the hinge axis is vertical to prevent the connecting section from rotating due to gravity. Then, fit the positioning section onto the positioning boss to fix the transducer bracket and weld it. After welding, rotate the watch case along its central axis to make the hinge axis horizontal, or take an additional rod-like object and insert it into the tube to poke the connecting section, eventually causing relative rotation between the connecting sections, shortening the distance between the positioning sections at both ends, so that the positioning section can be dislodged from the transducer bracket fixing boss and then taken out from the outlets at both ends of the watch case.

[0024] A welding auxiliary tooling is used to ensure that the central axes of the two ultrasonic reflection channels coincide when welding the base of an ultrasonic water meter. It includes a bifurcated section for inserting into the ultrasonic reflection channel and a limiting section with one end fixedly connected to the bifurcated section and the other end extending out of the meter casing and limiting the axial position of the bifurcated section.

[0025] Before welding, place the watch case horizontally, insert the welding auxiliary tooling into the watch case, and extend the bifurcated section from the reserved opening of the transducer bracket fixing boss. At this time, the limiting section is just stuck on one end of the watch case. Then, extend another welding auxiliary tooling from the other end of the watch case and extend it out of the reserved opening of another transducer bracket fixing boss. Then, use the two bifurcated sections to position and fix the transducer bracket fixing boss, and then perform welding. After welding is completed, remove the welding auxiliary tooling from the two ends of the watch case.

[0026] Compared with the prior art, the advantages of the present invention are:

[0027] Since both the ultrasonic transducer and the reflector are mounted on the transducer bracket, they do not occupy the ultrasonic reflection channel. This allows the cross-sectional radius of the ultrasonic reflection channel to be minimized, thereby reducing the impact on the water flow channel and minimizing interference sources such as eddies and cavitation that affect ultrasonic measurement. The software algorithm is simple and the measurement is accurate. By calculating the flow velocity through the ultrasonic paths on both the upstream and downstream sides, the transmission line length is increased, improving measurement accuracy and reducing the requirements for the transducer. Attached Figure Description

[0028] Figure 1 This is a three-dimensional schematic diagram of Embodiment 1 of the present invention;

[0029] Figure 2 This is a partially cut-away schematic diagram of Embodiment 1 of the present invention;

[0030] Figure 3 This is a three-dimensional schematic diagram of the installation process in Embodiment 1 of the present invention;

[0031] Figure 4 This is a three-dimensional schematic diagram of the watch without any components installed after the watch case has been removed, according to Embodiment 1 of the present invention.

[0032] Figure 5 This is a three-dimensional schematic diagram of half of the main waterway section in Embodiment 1 of the present invention;

[0033] Figure 6 This is a three-dimensional schematic diagram of the transducer bracket after the device of the present invention has been installed;

[0034] Figure 7 This is a cross-sectional schematic diagram of the welding auxiliary tooling in use according to Embodiment 2 of the present invention;

[0035] Figure 8 This is a cross-sectional schematic diagram of the welding auxiliary tooling 2 in use according to Embodiment 2 of the present invention.

[0036] In the diagram: 1. Casing; 11. Main waterway; 12. Ultrasonic reflection channel; 2. Ultrasonic transducer; 3. Reflecting column; 31. Reflecting surface; 4. Transducer bracket; 41. Flange; 42. Transducer sealing ring; 5. Transducer bracket fixing boss; 5. Sealing surface; 51. Bracket sealing ring; 52. Temperature sensing boss; 6. Temperature sensing sealing ring; 61. Reserved sensor boss; 7. Acceleration pipe; 8. Circuit board box; 9. Signal line; 91. Positioning section; 101. Connecting section; 102. Branching section; 111. Limiting section; 112. Detailed Implementation

[0037] To make the technical means, creative features, objectives and effects of this invention easier to understand, the following description, in conjunction with the accompanying drawings and specific embodiments, further explains how this invention is implemented.

[0038] Example 1, as Figure 1-6 As shown, an ultrasonic water meter base is manufactured using a one-piece molding method, including a main water channel 11 formed by a casing 1, and also including:

[0039] Ultrasonic transducer 2, used for receiving and transmitting ultrasonic waves;

[0040] A reflection device for reflecting ultrasonic waves emitted by ultrasonic transducer 2 includes a reflection column 3, the upper end of which is a reflection surface 31, and the lower end of the reflection column 3 is interference-fitted onto transducer bracket 4.

[0041] Transducer bracket 4 is installed at the channel opening of ultrasonic reflection channel 12 away from the main waterway, and is used to install ultrasonic transducer 2 and reflection device;

[0042] The transducer bracket fixing boss 5 is used to connect the housing 1 and the transducer bracket 4. Two transducer bracket fixing bosses 5 are provided. Each transducer bracket fixing boss 5 is provided with an ultrasonic reflection channel 12. The central axes of the two ultrasonic reflection channels 12 coincide and intersect with the central axis of the main water channel 11. The angle of intersection is less than 90°.

[0043] Temperature sensing boss 6 is used to install a temperature sensor to measure the temperature of flowing water.

[0044] The reserved sensor protrusion 7 allows for easy installation of pressure sensors, ambient temperature sensors, and water quality sensors. It can also expand the instrument and functions as needed, thereby achieving the goal of monitoring multiple parameters with one water meter.

[0045] Acceleration pipe 8 is equipped with a variable diameter pipe section and an ultrasonic via is set at the corresponding position of ultrasonic reflection channel 12;

[0046] The circuit board box 9 contains circuit board box components and signal lines 91, which are used for transmitting signals, providing power, and performing ultrasonic calculations.

[0047] In use, after the ultrasonic transducer 2 on one side emits ultrasonic waves, they are reflected by the reflector and enter the ultrasonic reflection channel. After being reflected by the reflector on the other side, they are received by the ultrasonic transducer 2 on the other side. The ultrasonic transducer 2 on the other side then emits ultrasonic waves, which enter the ultrasonic transducer 2 on the opposite side through the opposite path. This detects the time difference caused by the change in speed when the ultrasonic beam propagates in the water upstream and downstream. The analysis and processing are then used to obtain the water flow rate and further calculate the water flow rate.

[0048] The housing 1, transducer bracket fixing boss 5, temperature sensing boss 6, reserved sensor boss 7, and acceleration pipe 8 are made in one piece, such as by casting or die casting. They can be made entirely in one piece, or they can be made into two identical parts and then combined for installation, which facilitates the installation of parts.

[0049] For sealing purposes, the transducer bracket fixing boss 5 has a sealing surface 51 at its end for placing the bracket sealing ring 52. Correspondingly, the transducer bracket 4 has a flange 41, and the transducer bracket 4 is fastened to the transducer bracket fixing boss 5 with screws. The transducer bracket 4 is provided with a transducer sealing ring 42 to ensure the sealing effect of the ultrasonic transducer 2. The temperature sensing boss 6 is provided with a temperature sensing sealing ring 61.

[0050] If the two identical outer shells are molded as one piece, during installation, place the bracket sealing ring 52 on the sealing surface 51 of the transducer bracket fixing boss 5 on one half of the shell 1. After aligning the flange 41 of the transducer bracket 4, tighten the transducer bracket 4 and the transducer bracket fixing boss 5 with screws. Insert the reflector column 3 into the transducer bracket 4 with an interference fit, check the optical path and ensure that the centers of the two reflector surfaces 31 are aligned. Then, place the transducer sealing ring 52 in the corresponding position of the transducer bracket 4 and press in the ultrasonic transducer 2. Install the temperature sensing sealing ring 61 on the temperature sensing boss 6 and screw the temperature sensor into the threaded connection of the temperature sensing boss 6. Connect the signal line 91 of the ultrasonic transducer 2, the signal line of the temperature sensor, etc. to the junction box and fix the circuit board box on the transducer bracket 4. Finally, install the other half of the shell 1 in the corresponding position with bolts.

[0051] When the method of separating and molding the watch case 1 is adopted, the watch case 1 can be processed and formed by conventional methods such as turning, milling, and drilling, which is easy to achieve and has low difficulty; while the transducer bracket 4, the reflector column 3, the ultrasonic transducer, and the sealing ring can be modularly pre-assembled into components, thereby improving production efficiency.

[0052] Since both the ultrasonic transducer 2 and the reflector are mounted on the transducer bracket 4, they do not occupy the ultrasonic reflection channel 12. This allows the cross-sectional radius of the ultrasonic reflection channel to be minimized, thereby reducing the impact on the water flow channel and minimizing interference sources such as eddies and cavitation that affect ultrasonic measurement. The software algorithm is simple and the measurement is accurate. By calculating the flow velocity through the ultrasonic paths on both the upstream and downstream sides, the transmission line length is increased, improving measurement accuracy and reducing the requirements for the transducer. Accelerating the flow through the pipeline increases the water flow velocity, thereby reducing the sensitivity of the flow velocity measurement equipment and lowering the accuracy requirements for measurement equipment such as the ultrasonic transducer 2.

[0053] Example 2 differs from Example 2 in that it is manufactured using a welding method to accommodate materials that are difficult to mold in one piece. The transducer bracket fixing boss 5 is welded to the watch case 1, and the transducer bracket 4 is welded to the transducer bracket fixing boss 5. The watch case is generally divided into two identical parts, which are fixed together with screws during installation.

[0054] To facilitate the welding of the transducer bracket fixing boss 5 to the housing 1, the transducer bracket fixing boss 5 is equipped with two types of welding auxiliary fixtures to ensure that the central axes of the two ultrasonic reflection channels coincide.

[0055] Welding auxiliary tooling as Figure 7 As shown, it includes a positioning section 101 for inserting into the ultrasonic reflection channels at both ends, and a plurality of mutually hinged connecting sections 102 for hinged to the two positioning sections 101. The number of connecting sections 102 is at least two, and the hinge axes of the hinges are in the same direction.

[0056] Before welding, place the watch case 1 horizontally. Straighten the welding auxiliary fixture and insert it into the pre-drilled hole on the watch case 1 for mounting the transducer bracket fixing boss 5, until it protrudes from the pre-drilled hole on the other side. Figure 7 As shown in the diagram above, the positioning section 101 protrudes outside the watch case 1. The welding auxiliary fixture is kept horizontal, and the hinge axis is vertical to prevent the connecting section 102 from rotating due to gravity. Then, the positioning section 101 is fitted with the transducer bracket fixing boss 5 for welding. After welding, the watch case 1 is rotated along its central axis to make the hinge axis horizontal, or an additional rod-like object is inserted into the tube to poke the connecting section 102, ultimately causing relative rotation between the connecting sections 102, shortening the distance between the two positioning sections 101, and causing the positioning section 101 to disengage from the transducer bracket fixing boss 5. Figure 7 As shown in the diagram below, it is then removed from the outlets at both ends of case 1.

[0057] Welding auxiliary tooling two Figure 8As shown, it includes a bifurcated segment 111 for inserting into the ultrasonic reflection channel, and a limiting segment 112 with one end fixedly connected to the bifurcated segment and the other end extending out of the case 1 and defining the axial position of the bifurcated segment.

[0058] Before welding, place the watch case 1 horizontally, insert the welding auxiliary tooling into the watch case 1, and extend the forked section from the reserved opening of the transducer bracket fixing boss 5. At this time, the limiting section 112 is just locked on one end of the watch case 1. Then, extend another welding auxiliary tooling from the other end of the watch case 1, such as... Figure 8 As shown in the above figure, then extend the reserved opening of another transducer bracket fixing boss 5, as shown. Figure 8 As shown in the figure below; then, the transducer bracket fixing boss 5 is positioned and welded on the two bifurcated sections; after welding, the welding auxiliary tooling can be removed from the two ends of the casing 1.

[0059] The purpose of the welding auxiliary tooling is to enable the transducer bracket blank to be easily and accurately welded onto the housing, ensuring the straightness of the ultrasonic reflection channel 12. The auxiliary tooling is easy to remove and can be reused.

[0060] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Any simple modifications, alterations, and equivalent transformations made to the above embodiments based on the technical essence of the present invention shall still fall within the protection scope of the present invention.

Claims

1. An ultrasonic water meter base, comprising a main water channel formed by a meter casing, characterized in that, Also includes: Ultrasonic transducers are used to receive and transmit ultrasonic waves. A reflector, used to reflect ultrasonic waves emitted by an ultrasonic transducer; The transducer bracket is installed at the entrance of the ultrasonic reflection channel away from the main waterway. It is used to install ultrasonic transducers and reflection devices without occupying the ultrasonic reflection channel. A transducer bracket fixing boss is provided for connecting the casing and the transducer bracket. Two transducer bracket fixing bosses are provided. Each transducer bracket fixing boss is provided with an ultrasonic reflection channel inside. The central axes of the two ultrasonic reflection channels coincide and intersect with the central axis of the main water channel. The angle of intersection is less than 90°. The reflective device includes a reflective column, the upper end of which is a reflective surface, and the lower end of which is interference-fitted onto a transducer bracket. The end of the fixed boss of the transducer bracket is provided with a sealing surface for placing the bracket sealing ring, and the transducer bracket is provided with a corresponding flange.

2. The ultrasonic water meter base according to claim 1, characterized in that: In use, after the ultrasonic transducer on one side emits ultrasonic waves, they are reflected by the reflector and enter the ultrasonic reflection channel. Then, after being reflected by the reflector on the other side, they are received by the ultrasonic transducer on the other side. The ultrasonic transducer on the other side then emits ultrasonic waves, which enter the ultrasonic transducer on the opposite side through the opposite path.

3. The ultrasonic water meter base according to claim 1 or 2, characterized in that: The watch case is also equipped with a temperature sensing boss and a reserved sensor boss.

4. The ultrasonic water meter base according to claim 3, characterized in that: The casing is also equipped with an acceleration pipe, which has a variable diameter section and an ultrasonic via is provided at the corresponding position of the ultrasonic reflection channel.

5. The ultrasonic water meter base according to claim 3, characterized in that: The temperature sensing boss, the reserved sensor boss, the housing and the transducer bracket fixing boss are integrally molded. The transducer bracket is equipped with a transducer sealing ring to ensure the sealing effect of the ultrasonic transducer. The temperature sensing boss is equipped with a temperature sensing sealing ring, and the temperature sensor is screwed into the threaded connection of the temperature sensing boss.

6. The ultrasonic water meter base according to claim 4, characterized in that: The transducer bracket fixing boss is welded to the watch case, and the transducer bracket is welded to the transducer bracket fixing boss.

7. The ultrasonic water meter base according to claim 4, characterized in that: The temperature sensing boss and the reserved sensor boss are welded to the watch case.

8. The ultrasonic water meter base according to claim 1 or 2, characterized in that: It also includes a circuit board box, which contains circuit board box components and signal lines.

9. A welding auxiliary tooling, used in welding the ultrasonic water meter base as described in claim 1, for ensuring that the central axes of the two ultrasonic reflection channels coincide, characterized in that: It includes positioning segments for insertion into the ultrasonic reflection channels at both ends, and several interconnected connecting segments for hinged connection of the two positioning segments, wherein the number of connecting segments is at least two, and the hinge axes of the hinges are in the same direction.

10. A welding auxiliary tooling, used in welding the ultrasonic water meter base as described in claim 1, for ensuring that the central axes of the two ultrasonic reflection channels coincide, characterized in that: It includes a bifurcated section for inserting into the ultrasonic reflection channel, and a limiting section that is fixedly connected to the bifurcated section at one end and extends out of the case at the other end, defining the axial position of the bifurcated section.

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