Flow meter

Abstract

Disclosed is a flow meter that can be implemented with different nominal diameters DN and installation lengths LL and with minimal device complexity.

Description

[0001] Flow meter

[0002] Description

[0003] The invention relates to flow meters for measuring the flow of fluids in a pipeline.

[0004] Flow meters can, for example, have two ultrasonic transducers that are attached to a section of pipe at a distance from each other as a so-called "clip-on" solution, with both transducers acting as transmitters and receivers. The measurement signals are coupled obliquely through the pipe wall into the fluid. A disadvantage of clip-on flow meters is that the measurement signals penetrate the wall of the measuring channel, so that different materials used to construct the measuring channel can result in different measurement signals, meaning that the influence of the material must be taken into account when evaluating the measurement signal.

[0005] Solutions are also known that use a measuring insert in which the ultrasonic transducers are housed. This measuring insert is placed into a recess in a pipe section / flow channel, whereby the actual measuring channel can also be part of this measuring insert.

[0006] Documents DE 20 2016 008 775 U1 , WO 2016 / 012 024 A1 , EP 3 677 877 A1 and EP 3 172 539 B1 each disclose flow meters in which a measuring channel is formed by an approximately cylindrical insert that is axially inserted into the pipe section of the housing.

[0007] Such flow meters have the disadvantage that the geometry of these measuring inserts is very limited, since axial insertion requires that the measuring insert and the measuring channel be designed without undercuts. Furthermore, butting in the inlet and outlet areas is difficult to achieve or only possible with a considerable wall thickness of the measuring insert. EP 2 888 560 A1 describes a flow meter in which the two ultrasonic sensors are also arranged in a closed housing that extends into a measuring channel through a radial recess. These recessed sections, in turn, disrupt the flow through the measuring channel. Furthermore, these recessed sections of the housing serve to position a measuring insert within the measuring channel. This measuring insert carries reflectors for deflecting the measuring beams.Similar to the solutions described above, the measuring channel and the measuring insert must be coordinated in such a way that axial, end-face insertion of the measuring insert is possible.

[0008] In WO 2018 / 011 371 A1, which originates from the applicant, a flow meter is described in which the coupling in and out of measurement signals from two spaced-apart measuring sensors is carried out via a common coupling piece or a coupling piece for each sensor, which carries the sensor(s) / transducer(s).

[0009] Parallel patent application WO 2018 / 011 372 A1 describes a flow meter with an oval or trapezoidal measuring channel.

[0010] Both flow meter concepts ensure improved flow through the flow meter compared to the aforementioned state of the art, with increased measurement accuracy.

[0011] In the applicant's publication WO 2022 / 079 213 A1, a further development of the aforementioned concept is disclosed, in which inlet- and outlet-side inserts are first inserted radially through a recess in a flow channel base body and then moved axially to their predetermined end position. Subsequently, a multi-part measuring channel insert is also inserted radially through a recess in a base body, so that it is positioned in the area between the inserts. The reflectors required to form the signal path are integrated into the measuring channel insert by injection molding (overmolding). Such a concept can be advantageously used with comparatively small nominal diameters.For larger nominal diameters, a problem can arise in that a comparatively large volume must be provided in the flow channel to accommodate the radially inserted inserts and the multi-part measuring channel housing.

[0012] According to a subsequently published patent application by the applicant, this disadvantage can be avoided by inserting a measuring channel insert – as in the solutions described above – which at least partially limits a measuring channel section, radially through a recess in the flow channel base body, whereby an inlet and an outlet insert are first inserted axially into the flow channel and then fixed in position by means of the measuring channel insert, so that the flow meter, in particular the base body forming the flow channel, can be designed to be very compact with a small installation volume.

[0013] However, a disadvantage of this concept is that the construction of the measuring channel insert and the positioning of the control housing on the flow channel base body requires a high level of manufacturing and assembly effort.

[0014] In contrast, the invention is based on the objective of optimizing the flow meter with a view to further reducing the assembly and device-related effort.

[0015] This problem is solved by a flow meter with the features of claim 1.

[0016] Further aspects of the invention are defined by claims 5, 6, 13, 14, 19 and 21.

[0017] Advantageous embodiments of the invention are the subject of the dependent claims. The concept defined in claim 1 provides for a flow meter having a flow channel base body, also called a "body," which can be attached to a pipe through which a fluid flows. This base body is manufactured, for example, by casting from a brass alloy or a metal alloy. In principle, this base body can also be made of a composite material. A measuring unit is mounted on this base body. This unit has at least two spaced-apart sensors (transducers), which are preferably designed as ultrasonic transducers. The measuring signals of these sensors can be coupled into a measuring channel, preferably through at least one recess in the base body, and can be coupled out via reflectors.The flow meter is further equipped with control electronics housed in a control enclosure for controlling the sensors and processing the measurement signals. The measuring channel is formed, at least in sections, by a measuring channel insert that passes through a recess in the base body. Upstream and downstream of the base body, fluid inlets and outlets are provided, attached to the base body and, according to a first aspect of the present application, connected to it by force or material bonding. By appropriately designing the separately manufactured fluid inlet and outlet, the lay length (LL) can thus be easily changed or adapted to the existing pipeline while maintaining the same geometry of the flow channel base body.

[0018] It is particularly preferred if the fluid inlet and fluid outlet, which can be attached to the base body, are each equipped with a fitting, preferably a threaded fitting, for connection to the pipeline.

[0019] Adjusting the installation length LL is particularly easy if pipe sections for adjusting the installation length LL are provided between such a fitting and the base body. The connection of the pipe sections to the base body on the one hand and the fitting on the other is preferably force-fit or material-fit. Secondly, the control housing of the generic flow meter is designed such that the sensors and the components of the control electronics, including the power supply, in particular the battery, its holder, covers, and other functional components, can be inserted sequentially in the vertical direction, i.e., transversely to the longitudinal axis of the measuring channel, into the control housing, thus significantly reducing the assembly effort compared to the aforementioned prior art.

[0020] The connection / fixing / contacting of components can be achieved using holders, such as those with spring clips or form-fitting receptacles for positioning the components within the housing. A material-bonded connection of components, for example by gluing or welding, is also possible.

[0021] According to a further aspect of the invention, the assembly and tooling effort can be minimized if the control housing and the measuring channel insert of the generic flow meter are designed monolithically or as a single-piece structure made of materially bonded components. With such a concept, the control housing and the measuring channel insert can then be connected as a unit to the flow channel base body, thus enabling precise assembly with minimal effort. A measuring channel roof (upper part) can be formed integrally with the control housing, with a measuring channel lower part then being connected to the measuring channel roof, e.g., by ultrasonic welding. The reflectors can be integrated by overmolding.

[0022] The control housing (with integrated measuring channel insert) is preferably fixed in position to the flow channel base body by means of tangential bolts inserted into a body interface of the base body such that the control housing is precisely fixed in position relative to the base body. It is preferred that the control housing has two spaced-apart cheeks on the base body side, which laterally engage the body interface of the base body. Several, preferably three, tangential bolts can be used for this purpose, inserted into the body interface on both sides. In an alternative solution, several such tangential bolts are each formed on a bolt body, which is then attached to the body interface as a whole. These tangential bolts can be designed, for example, as fitted bolts, threaded bolts, or in some other way.

[0023] In one variant of the invention, these tangential bolts or the bolt body are secured against accidental or intentional damage by means of a protective cover.

[0024] Such a concept, with tangential bolts inserted on both sides using a press fit, requires significantly less space than conventional concepts in which the control housing is fixed in position by means of bolts running parallel to the measuring channel axis, requiring corresponding receptacles for these long bolts on the base body. The concept according to the invention makes it possible to design the bottom area of ​​the control housing, i.e., the area to which the measuring channel insert is attached, with a larger volume than in the prior art.

[0025] In a particularly simple embodiment, the position is fixed on both sides by means of three bolts spaced apart from each other, which are inserted into corresponding recesses / openings in the base body and the measuring channel insert.

[0026] In one embodiment of the flow meter, the control housing in the area of ​​an EDU (Electronic Display Unit) is covered by a cover glass, which is connected to the control housing via a seal. This seal can be applied to the cover glass during assembly or integrated into a receptacle in the control housing. For further securing, a one-piece sealing frame is preferably positioned, which connects and seals the control housing and the cover glass, and which is preferably bonded to the control housing by ultrasonic or laser welding or by a suitable snap-fit ​​connection.

[0027] To prove that such a flow meter complies with a Measuring Instruments Directive (MID), a MID seal can be applied in the area of ​​the butt joint between sealing tubes and control housing by thermal or plastic deformation.

[0028] According to a fourth independent aspect of the invention, the generic flow meter can be equipped with control electronics in which a commonly used main circuit board (PCB) is divided into a metering board and a user interface (UI) board (power management). These two boards, together with a communication module, are mounted vertically offset within the control housing. The metering board—hereinafter referred to as the MET board—is designed with optimized metering algorithms for controlling the sensors and evaluating the measurement signals. This concept allows the control electronics to be integrated into the control housing with minimal space requirements. The positioning and contacting of these boards is preferably achieved by means of spring clips and / or positive-locking mounts.

[0029] According to a further independent aspect of the invention, the flow channel body and the measuring channel insert, which is formed integrally with the control housing, are designed such that the sensor positioning, in particular the sensor spacing, the sensor angle of incidence, and the distance between the sensor and the adjacent reflector in the flow direction remain the same for different nominal diameters (DN). In this way, it is possible to harmonize the measuring channel geometry for different nominal diameters (DN) and also installation lengths (LL). This harmonization is further optimized if the geometry of a control housing-side measuring channel roof is the same for the sensor positioning / signal coupling and reflector position for several nominal diameters (DN) and installation lengths (LL).

[0030] It is particularly preferred if the width of the measuring channel roof remains constant regardless of the nominal diameter (DN). The flow cross-section can then be adjusted, for example, by designing a rectangular measuring channel cross-section, whereby the height (perpendicular to the measuring channel roof) is varied depending on the nominal diameter (DN).

[0031] Securing the position of a battery for the power supply of the control electronics is particularly easy if a two-part battery holder is provided, consisting of a lower and upper battery holder part, which are inserted into the control housing in a force-fit and / or form-fit direction and connected to each other in order to support the battery.

[0032] Such a battery can be connected to the PCB or PCB modules, for example, via a plug connection, by soldering, or via spring contacts.

[0033] In the concept according to the invention, it is preferred to integrate the reflectors into the measuring channel in a material-bonded manner, for example by overmolding, in order to further harmonize the measuring channel structure.

[0034] According to the invention, the control housing can be designed in such a way that, except for a measuring channel lower part, it remains the same for all nominal diameters and overall lengths.

[0035] The concept according to the invention enables extremely simple assembly of the flow meter, whereby in particular the control housing with the control electronics components housed therein can be mounted vertically without screws. According to a further independent aspect of the invention, the reflector can be designed as a preferably cylindrical, bolt- or helical-shaped insert body, which is inserted into a receptacle open towards the measuring channel in a measuring channel wall, wherein the reflector surface is formed on the outer circumference of the insert body.

[0036] This reflector surface can be formed on an end face of the insert body. Alternatively, the reflector surface can also be provided on a tangential or diagonal surface. This is preferably formed by a reflector groove that runs transversely to the longitudinal axis of the insert body. The receptacle for the insert body can be designed such that the insert body is received with its end sections in the side walls of the measuring channel insert, and the reflector surface formed by the reflector groove forms a section of a top or bottom surface of the measuring channel. The length of the reflector groove is then preferably selected so that it corresponds approximately to the width of the measuring channel. Side surfaces of the reflector groove can also form partial sections of the measuring channel wall.

[0037] In the alternative solution, the reflector surface is formed on an end face of an insert body, which is preferably helical and screwed into a threaded receptacle in the measuring channel roof or base, so that the reflector surface in turn forms a section of a bottom or roof surface. Hybrid forms of the two concepts described above (insert body with reflector surface in a reflector groove and insert body with an end-face reflector surface) can also be implemented.

[0038] To seal the intake against the measuring channel, at least one reflector seal is preferably provided on the outer circumference of the insert body.

[0039] A further independent aspect of the invention is directed towards the measurement channel insert being formed on a compact measurement channel module, into which the reflectors and fastening means for positioning on the base body are integrated and on which the sensors are also pre-mounted, so that the measurement channel module can be inserted as a pre-assembled compact unit into the base body and the control housing, which is preferably formed integrally with it. Accordingly, the receptacles for the reflectors and the sensors are also formed in this measurement channel module. The measurement channel module can consist of several components, which are then joined, mounted, or materially bonded, e.g., by ultrasonic welding, in a suitable manner, so that the measurement channel module with the reflectors and the measurement channel insert is formed integrally, i.e., as a single, assembled structural unit, and only the sensors (ultrasonic transducers), if applicable, need to be added.They must be mounted with the sensor boards to provide a pre-assembled compact unit.

[0040] The base body, the associated control housing, and the measuring channel module are geometrically designed such that the measuring channel module can be inserted into the base body through the radial recess and is precisely fitted there. Positional fixation is achieved by suitable fixing elements, for example, three fixing pins that engage in locking recesses and are secured there, or by a material bond. Additionally or alternatively, positional fixation can also be achieved without such fixing elements by a material bond between the measuring channel module and the control housing / base body. The radial recess is preferably covered by the housing-side area of ​​the measuring channel module.

[0041] Preferably, the measuring channel has a rectangular cross-section and / or the reflectors are integrated into the measuring channel housing by overmolding.

[0042] Thus, a flow meter is revealed in which a control housing is formed as a single unit with a measuring channel insert. Furthermore, the flow channel base body has a modular design, so that flow meters with different installation lengths (LL) can be produced by selecting appropriate pipe sections.

[0043] Also revealed is a flow meter with control electronics designed so that its components can be inserted into the control housing vertically, essentially without additional tools or screws.

[0044] Furthermore, a concept has been revealed that makes it possible to harmonize the signal path characteristics and the channel structure for different nominal diameters DN and installation lengths LL.

[0045] Furthermore, a flow meter is revealed in which at least one reflector is designed as an insert body placed in a receptacle.

[0046] Also revealed is a flow meter with a compact measuring channel module, into which the measuring channel insert is integrated and in which the reflectors are housed and the sensors are pre-mounted. This pre-assembled compact measuring channel module is then inserted into the base body or the control housing, whereby these components can also be manufactured as single pieces or monolithically.

[0047] Preferred embodiments of the invention are explained in more detail below with reference to schematic drawings. These show:

[0048] Figure 1 shows a three-dimensional representation of an embodiment of a flow meter according to the invention;

[0049] Figure 2 shows an exploded view of the components of the flow meter according to Figure 1;

[0050] Figures 3 and 4 show sectional views of two flow meters according to the invention with different installation lengths (LL);

[0051] Figure 5 shows a detailed view of a control housing of the flow meter according to Figures 3 and 4; Figure 6 shows a schematic diagram to illustrate the adaptation of the measuring channel cross-section to the nominal diameter (DN);

[0052] Figure 7 shows a schematic representation of harmonized signal paths of flow meters or measuring channels with different nominal diameters (DN);

[0053] Figures 8, 9 and 10 show ways to connect a measuring channel base to a measuring channel roof;

[0054] Figure 11 shows a single view of a flow channel base body of a flow meter according to the preceding figures;

[0055] Figure 12 shows ways to connect a pipe section to an ultrasonic transducer base body according to Figure 11;

[0056] Figure 13 shows an embodiment of a flow meter in which a check valve is positioned in the area of ​​a fluid inlet / outlet;

[0057] Figure 14 shows a detailed illustration to clarify how the control housing is fixed in position on the ultrasonic transducer base body by means of tangential bolts;

[0058] Figure 15 shows a variant of a tangential bolt for fixing the position of the control housing in relation to the ultrasonic transducer base body;

[0059] Figures 16a, b, c show an embodiment of a flow meter according to the invention, in which the position fixing is achieved via a bolt body and a corresponding protective cover;

[0060] Figure 17 shows a view of an opened control housing in an embodiment where the sensors are connected to the control electronics via electrical wires and a plug connection; Figure 18 shows a variant where two sensors are connected to a plug connector via a flexible PCB;

[0061] Figure 19 shows an embodiment in which a main PCB is contacted with a battery via contact springs;

[0062] Figure 20 shows an alternative embodiment in which the battery is connected to the main PCB via contact tabs, the connection being made by soldering;

[0063] Figure 21 shows a schematic diagram to illustrate the application of a seal to a cover glass;

[0064] Figure 22 shows a schematic representation in which, as an alternative to the concept according to Figure 21, a seal is integrated into the control housing;

[0065] Figures 23 and 24 show alternative ways of fixing the cover glass to the control housing by means of a sealing frame;

[0066] Figures 25 and 26 show alternative ways of joining a sealing frame to the control housing and attaching a MID seal;

[0067] Figure 27 Alternatives for positioning desiccant inside the control housing;

[0068] Figure 28 shows an embodiment of a flow meter according to the invention, in which the main PCB is divided into a MET board and a UL board;

[0069] Figures 29 to 44 show assembly steps for forming a flow meter according to the invention with the components described above;

[0070] Figures 45a to 45d show views of an embodiment of a flow meter with a compact measuring channel module; Figures 46a to 46c show an embodiment of a flow meter in which a control housing is combined with a base body;

[0071] Figures 47a to 47c show an embodiment of a flow meter in which the reflectors are formed by insert bodies;

[0072] Figure 48 shows a variant of the embodiment according to Figures 47a to 47c and

[0073] Figures 49a to 49c show another variant of the embodiment according to Figures 47a to 47c.

[0074] A first embodiment of a flow meter 1 according to the invention is shown in Figure 1. Accordingly, this flow meter 1 has a flow channel base body, hereinafter referred to as base body 2, made of cast brass or another alloy, to which a control housing 4 is attached. The control housing 4 extends into the interior of the base body 2 with a measuring channel insert. This will be discussed in more detail below. The control housing 4 is shown transparently in Figure 1, so that internal control electronics with two sensors (not shown in Figure 1), a power supply / battery 8, a main PCB 10 (printed circuit board), and an EDU 12 are visible. The latter is covered by a cover glass 14 and an underlying ID plate 16. The upper end of the control housing 4 in Figure 1 is formed by a sealing tube 17, which fixes the cover glass 14 in position relative to the control housing 4.

[0075] The base body 2 has an inlet port 18 and an outlet port 20, each connected by a press fit, a screw connection, or a material-fit connection to a pipe section 22, 24, at the end section of each pipe section furthest from the base body 2, a threaded fitting 26, 28 is attached. The connection between the threaded fitting 26, 28 and the corresponding pipe port 22, 24 is also made by a press fit, a screw connection, or a suitable material-fit connection. By varying the length of the pipe section, the overall length LL of the flow meter 1 can be varied accordingly without changing the geometry of the base body 2.

[0076] Further details of the flow meter 1 can be seen from the exploded view in Figure 2. As explained above, the axial end sections of the brass base body 2 are formed by the inlet nozzle 18 and the outlet nozzle 20. As shown in Figure 2, a radially projecting body interface 30 is provided on the base body 2, via which the control housing 4 can be fixed in position on the base body 2. This will be explained in more detail below. The control housing 4 has two spaced-apart cheeks 34a, 34b on its bottom 32 facing the base body 2, which laterally encompass the body interface 30, so that the housing 4 and the body interface 30 or the base body 2 can be connected by tangential bolts 36 inserted in the tangential direction or alternatively by a bolt plate 38 carrying several bolt sections, which passes through recesses in the cheeks 34a, 34b and the body interface 30.The bolts 36 or the bolt plate 38 are covered by a protective cover 40, so that access to these locking elements is prevented or at least made more difficult.

[0077] As explained above, a pipe section 22, 24 is press-fitted into each of the nozzles 18, 20, whereby the overall length LL can be easily varied by varying the pipe section length while keeping the base body 2 constant – as described above. Figure 2 also shows the two threaded fittings 26, 28, which are likewise press-fitted to the pipe section 22, 24. The pipe section 22, 24 engages in a corresponding bore of the threaded fitting 26, 28 or the nozzle 18, 20, respectively.

[0078] Also visible in Figure 2 are an inlet insert 40 and an outlet insert 42, which are inserted axially into the base body 2 and thus form part of the measuring channel, which will be explained in more detail below. GW0516P-WQ-0019

[0079] - 16 -

[0080] In the area between the two cheeks 34a, 34b, a measuring channel roof Z-upper part 44 is formed on the base 32 of the control housing 4. This upper part, together with a measuring channel lower part 46, forms a measuring channel insert 80 (see Figure 3). When the flow meter 1 is mounted, this insert extends through a radial recess 48 of the body interface 30 into the flow channel of the base body 2, thus forming a measuring channel 82 (see Figure 3) with a defined cross-section. In the exploded view according to Figure 2, reflectors are identified by reference numeral 50 (only one of which is marked with a reference numeral). These reflectors are integrated into the measuring channel roof 44 and the measuring channel lower part 46 by injection molding / overmolding.

[0081] In the illustration according to Figure 2, two ultrasonic transducers 52, 54 are also visible, which are connected via a flexible PCB 56 to a connector 58. This connector 58 then makes contact with the main PCB 10, which is equipped with a corresponding connector part 60. The connector 58 and the connector part 60 are also indicated in Figure 1.

[0082] As explained above, the control housing 4 is covered at the top (view according to Figure 2) by a cover glass 14, which rests on an annular end face of the control housing 4 with a seal 62, thus sealing it at the top. Further sealing / positional fixation is achieved by the sealing frame 17, which connects the cover glass 14 to the control housing 4 by means of a force-fit or form-fit connection.

[0083] As explained, the battery 8 is housed inside the control housing 4. For this purpose, a battery holder base 64 is provided on the base 32 of the control housing 4. This base surrounds the two ultrasonic transducers 52 and 54 and forms a support for the battery 8. Two spring tabs 67 are provided on the circumferential wall of the battery holder base 64, which secure the battery holder base 64 in position within the control housing 4. The battery 8 is connected to the main PCB 10 via suitable contacts – this will be discussed in more detail later. GW0516P-WQ-0019

[0084] - 17 -

[0085] The main PCB 10 has four recesses 66 in its corner areas, into which a pin 68 of the battery holder base 64 is inserted during assembly, thus also securing the main PCB 10 in its position. This is contacted in a known manner with the EDU 12, which can be read through a window 70 of the ID plate 16. Further securing of the main PCB 10 and the battery 8 is achieved by a battery holder top 72, which is supported on the pins 68 by support legs 75 and is laterally secured in the control housing 4 by spring clips 74, so that the battery 8 and the main PCB 10 are securely held in the control housing 4. As shown in Figure 2, the battery holder upper part 72 is also frame-shaped and engages the EDU 12. A communication module 76 is also supported on the battery holder upper part 72, which enables a wireless data connection with a base station or the like.This communication module 76 is also connected to the main PCB 10 and the battery 8 via suitable lines for power and data. In the representation according to Figure 1, the communication module 76 is covered by the ID plate 16, on which the cover glass 14 rests.

[0086] Figures 3 and 4 show sectional views of a flow meter 1 according to the invention with the same nominal diameter (DN 15) and different overall lengths LL. In the embodiment with a short overall length LL shown in Figure 3, the two threaded fittings 26, 28 are inserted directly into the inlet port 18 and outlet port 20 of the base body 2, respectively. As explained, this joining can be carried out via an interference fit or by soldering or the like. In the illustrated embodiment, it is preferred if the insertion is carried out via an interference fit, whereby, for example, the part to be inserted, i.e.,In the present case, the threaded fittings 26, 28 with their recesses 78 (only one recess is shown with reference numeral 78 in Figure 3) which engage in the nozzles 18, 20 are cooled (for example, to approximately -70°C) and then inserted into the receptacles of the nozzles 18, 20. After warming to ambient temperature, a sufficient press fit, capable of withstanding even high loads, is ensured. Accordingly, the manufacturing of these mating surfaces must be of suitable quality. As explained above, the control housing 4 is formed integrally with the measuring channel insert 80, which consists of the measuring channel 44 and the measuring channel base 46, and is inserted into the base body 2 through the radial recess 48 of the body interface 30, so that the latter is formed with a defined measuring channel 82.In this, two reflectors 50a, 50c are provided on the lower side of the measuring channel and a further reflector 50b on the upper side of the measuring channel, resulting in a W-shaped signal path. The two sensors 52, 54 and their sensor boards 84, 86 with the associated flexible PCB 50 are mounted on the base 32 of the housing 4, with the positioning being fixed, as described in the aforementioned prior art, by means of fixing pins 83 (only one of which is provided with a reference numeral in Figure 3) that pass through the sensors 52, 54 and the sensor boards 84, 86 and through corresponding recesses in the sensor boards 84, 86 and the sensors, respectively.

[0087] As can be further seen in Figure 3, the inlet insert 40 and the outlet insert 42 are inserted axially into the base body 2, so that they are arranged at the end face in extension of the measuring channel 82 and also project into the threaded fittings 26, 28, so that the butt joint between the base body 2 and the two threaded fittings 26, 28 is covered by the inserts 40, 42.

[0088] As explained above, the battery 8 is supported on the battery holder base 64, which rests on the base 32 of the control housing 4, with the two spring tongues 67a, 67b each engaging an undercut 88a, 88b, thus fixing the battery holder base 64 in position. As explained above, in this embodiment, the battery 8 is connected to the main PCB 10 via contact tabs / contact pins 90a, 90b, which, as explained above, is supported on the pins 68 of the battery holder base 64.

[0089] The upward positioning (view according to Figure 3) is achieved via the battery holder upper part 72, which, with its two laterally arranged spring clips 74, each engages further undercuts 92a, 92b on the control housing side, so that the battery holder upper part 72 secures the main PCB 10 and the battery 8 in position, the battery holder upper part 72 also being supported on the pins 68 of the battery holder lower part 64.

[0090] As can be seen in Figure 3, the communication module 76 is supported on the battery holder upper part 72. The EDU 12 is directly contacted with the main PCB 10 and at least partially supported by it. As explained, the ID plate 16 with its window 70 is located above the EDU 12. The cover glass 14 with the seal 62 then rests on this ID plate 16, with these components being fixed in position by the sealing frame 17, as explained above.

[0091] The flow meter with a longer overall length LL shown in Figure 4 can be manufactured according to the concept of the invention without modifying the control housing 4 and the base body 2. Depending on the desired overall length LL, a corresponding pipe section 22, 24 is attached to the inlet port 18 and the outlet port 20, preferably being press-fitted into the respective port 18, 20. The two threaded fittings 26, 28 are then also press-fitted onto the free end sections of the pipe sections 22, 24, with the threaded fittings 26, 28 being designed to correspond to the outer circumference of the pipe sections 22, 24. The pipe sections 22, 24 are preferably cylindrical without any steps, so that changing the overall length LL is possible with minimal technical effort.According to the invention, it is preferred if the pipe sections 22, 24, the threaded fittings 26, 28 and the nozzles 18, 20 are made of the same alloy or at least of a material with similar properties. Furthermore, the embodiment shown in Figure 4 corresponds to that shown in Figure 3, so that further explanations, particularly with regard to the design of the control electronics, are unnecessary.

[0092] Figure 5 shows a close-up view of the control housing 4 with the housing body 93, which is closed off from the base body 2 by the bottom 32. The previously described measuring channel insert 80 is formed on this bottom 32, which essentially consists of the measuring channel roof 44, which is manufactured integrally with the bottom 32, and GW0516P-WQ-0019

[0093] - 20 - the measuring channel lower part 46, which are connected to each other either by force-fit or - preferably - by material bonding and define the measuring channel 82 with a rectangular cross-section. Parallel to the side walls of the measuring channel insert 80, the two cheeks 34a, 34b are formed, which also project downwards (view according to Figure 6) from the base 32. In the illustrated embodiment, each cheek 34a, 34b is formed with three openings 94, into which - as explained in more detail below - the tangential bolts 36 are inserted to fix the control housing 4 to the base body 2.

[0094] As indicated in Figure 6, the cross-section of the measuring channel 82 in the concept according to the invention can be changed without significant modification of the control housing 4 by changing the height H, H' of the measuring channel lower section 46, while the width B of the measuring channel 82 remains constant. Accordingly, the geometry of the measuring channel roof 44 remains the same regardless of the nominal diameter DN and the overall length LL. This also means that the relative position of the two ultrasonic transducers 52, 54 to each other remains constant regardless of the nominal diameter DN and the overall length LL of the flow meter 1, so that the signal paths arising at different nominal diameters DN within the measuring channel 82 are harmonized. This is explained with reference to Figure 7.

[0095] This shows a schematic diagram of three measuring channels 82a, 82b, 82c with different nominal diameters DN, with the position of the two ultrasonic transducers 52, 54 also indicated. These are positioned at a slight angle on the base 32 of the control housing 4, so that the signals are coupled in and out at a slight angle as well. The reflectors 50a(a), 50a(b), 50a(c) opposite the ultrasonic transducer 52 are then positioned relative to each other according to the coupling angle of the ultrasonic transducer 52, so that the measuring signals are reflected by the reflectors 50a(a), 50a(b), 50a(c) at the same angle towards the central reflector 50b. The measurement signals are then reflected in the same way to the further reflectors 50c not shown in Figure 7 and deflected by them towards the further ultrasound transducer 54.Accordingly, the channel structure in the concept according to the invention is the same regardless of the nominal diameter DN and the installation length LL, so that a harmonized signal path characteristic 95 is formed, which significantly simplifies the evaluation via the control electronics 6 compared to conventional solutions with channel structures that vary depending on the nominal diameter DN.

[0096] Figures 8 to 10 illustrate ways to attach the measuring channel lower part 46 to the measuring channel roof 44.

[0097] In the variant shown in Figure 8, the lower measuring channel section 46 is connected to the measuring channel roof 44 by ultrasonic welding. According to the preceding descriptions, the measuring channel roof is formed integrally with the control housing 4 or its base 32. The dotted line indicates the resulting weld seam 96 in the transition area between these two components. The advantage of such a solution is that no complex interface for the mechanical connection of the components is required in the area of ​​this butt joint.

[0098] Figure 9 shows one way to mechanically connect the measuring channel roof 44 to the measuring channel base 46. Two sliding grooves 98a, 98b are formed on the measuring channel roof 44, into which fixing projections 100a, 100b (the latter not visible in Figure 9) formed on the measuring channel base 46 engage, so that the measuring channel insert 80 can be mounted by sliding the measuring channel base 46 into the sliding grooves 98a, 98b. This can again be achieved via an interference fit. Of course, a material-bonded connection can also be provided additionally or alternatively. However, such a concept requires a sufficiently robust design of the interface between the measuring channel roof 44 and the measuring channel base 46.

[0099] Figure 10 shows a simplified solution in which two slots 104a, 104b and 104c, 104d are formed on both sides of the support area 102 of the measuring channel base 46 on the measuring channel roof 44, into which a clamping profile 106 is inserted with preload / press fit. This approximately C-shaped clamping profile 106 can be manufactured, for example, by extrusion or as a stamped and bent part from sheet steel. The engagement between the clamping profile 106 and the associated slots 104 can also be designed with an undercut or the like to fix the clamping profile 106 in position.

[0100] Figure 11 shows a close-up view of the base body 2, which—as explained—can be used for different nominal diameters DN and overall lengths LL, thus minimizing the tooling effort. As explained, this base body 2 has an inlet nozzle 18 and an outlet nozzle 20 and a radial recess 48, which is encompassed by the body interface 30. Three recesses are formed on each of the side walls 108a, 108b of the body interface 30, of which only one is marked with reference numeral 110 in the illustration according to Figure 11. The spacing and geometry of the recesses 110 correspond to the relative arrangement of the openings 94 in the walls 34a, 34b, which, in the assembled state, precisely encompass the side walls 108a, 108b of the base body 2.Such a basic body 2 can be produced by casting with comparatively little effort, whereby only the fitting areas within the nozzles 18, 20 and within the body interface 30 encompassing the radial recess 48 need to be machined to ensure an exact fit with regard to the components used there (control housing 4, pipe section 22, 24, threaded fitting 26, 28, bolt 36).

[0101] Figure 12 illustrates several ways to fix a pipe section 22 to the base body 2.

[0102] In the embodiment shown in Figure 12a, a base body wall 111 of the base body 2 is designed with an increased wall thickness W on the inlet and outlet sides, wherein a radial extension 112 is provided to receive the pipe section 22, into which the end section of the pipe section 22 is inserted with a fit.

[0103] Figure 12b shows a more complex variant, in which the inlet or outlet nozzle is designed as a fitting projection 114. A corresponding fitting recess 116 is formed in the pipe section 22, into which the fitting projection 114 engages during assembly. Figure 12c shows an embodiment in which the inlet or outlet nozzle 18, 20 is formed on the base body 2, and the radial extension 112 is provided on the inner circumferential surface of this extension, into which the end section of the pipe section 22 is inserted.

[0104] Figure 12d shows a variant in which an opening in an inlet- or outlet-side base body wall 111 is continuously formed as a mating surface 118 into which the end section of the pipe piece 22 dips. The latter solution is characterized by an extremely simple design with sufficient strength.

[0105] To prevent backflow from flow meter 1 against the usual flow direction, a check valve can be provided on the inlet or outlet side. This check valve is typically mounted in the area of ​​threaded fittings 26, 28. The check valve should be supported circumferentially and end-face by the pipe section 22, 24 and the threaded fitting 26, 28.

[0106] Figure 13a shows a variant in which multiple steps are required for the pipe section 22, 24 – due to the considerable manufacturing effort, this variant is less preferred. Specifically, the pipe section 22, 24 has a stepped end section 122 on its outer circumference, which is press-fitted into the threaded fitting 26, 28. The inner circumferential surface of the pipe section 22, 24 has a radial extension 120 towards the threaded fitting 26, 28, into which the valve body of the check valve 126 extends. This stepped end section of the pipe section 22, 24 projects slightly radially into the space enclosed by the threaded fitting 26, 28, thus forming a support ring surface 124 for the check valve 126. Such a design requires complex machining of the pipe section 22, 24.

[0107] To overcome this disadvantage, it is proposed according to Figure 13b that the

[0108] Pipe section 22, 24 is designed with only a stepped end section 122 on its outer circumference, which extends into the threaded fitting 26, 28. The pipe section 22, 24 then extends radially into the interior enclosed by the threaded fitting 26, 28, thus forming a support ring surface 124 for supporting the check valve 126. With this solution, integrating the check valve 126 requires only a simple machining of the outer circumference of the pipe section 22, 24. In principle, however, it is also possible to connect the pipe section 22, 24 to the threaded fitting 26, 28 without radial extension or stepping and to integrate a check valve 126.

[0109] Figure 14 shows a partial view of a flow meter 1 according to the invention in the area where the control housing 4 is connected to the base body 2. As explained, two cheeks 34a, 34b are formed on both sides of the bottom 32 of the control housing 4, which overlap the body interface 30, specifically its side cheeks 108a, 108b. The control housing 4 is then fixed in position on the base body 2 on both sides by means of three tangential bolts 36 (see Figure 2), which are press-fitted into the openings 94 of the side cheeks 34a, 34b and the corresponding recesses 110 of the side cheeks 108.

[0110] In an embodiment shown in Figure 14, these bolts 36 are protected externally by protective covers 128, each of which is inserted into one of the openings 94 and thus covers the respective bolt 36. In principle, it is also sufficient to secure only one bolt 36 with such a protective cover 128. It is also possible to form corresponding recesses on the outside of the cheeks 34 into which the protective cover 128 is press-fitted.

[0111] Figure 15 shows a variant in which the opening 94 receiving the bolt 36 is provided with a receptacle 130 on the outside of the cheek 34, into which the protective cover 128 is press-fitted. To improve the positioning of the protective cover 128, a circumferential clamping rib 132 projecting towards the outer surface can be provided on its outer cover surface. When the protective cover 128 is inserted into the recesses 130, this rib folds over, thus reliably securing the protective cover 128 against intentional or accidental loosening.

[0112] In the embodiments described above, each cheek 34 is assigned three bolts 36, so that a relatively high assembly effort is required to insert the bolts 36 and the protective covers 128.

[0113] Figures 16a to 16c show a simplified solution in which the three bolts 36a, 36b, 36c are formed on a bolt body 134, which positions these three bolts 36a, 36b, 36c relative to each other so that they can be inserted in a single operation into the openings 94 of the cheeks 34 or into the recesses 110 of the side cheeks 108 of the body interface 30. According to Figure 16a, the bolt body 134 has an external frame structure 136 onto which a protective cover 128, covering the entire bolt body 134, can be placed, thus covering the bolts 36a, 36b, 36c and securing the bolt body 134 against removal or falling out. The geometry of the bolt body 134 is preferably adapted to the geometry of the adjacent cheek 34a, 34b. As shown in Figure 16c, complementary connecting means 138, 140 for position fixing can be provided on the protective cover 128 and on the bolt body 134.

[0114] Figure 17 shows a top view into the control housing 4, into which the main components of the control electronics 6 are not yet integrated. This illustration shows the two ultrasonic transducers 52, 54 supported on inclined surfaces of the base 32. In the illustrated embodiment, these transducers are connected via lines 142a, 142b to a connector 144, through which the ultrasonic transducers 52, 54, or their sensor boards, are in signal communication with the main PCB 10 or a metering board, which will be explained in more detail below.

[0115] An alternative solution is shown in Figure 18. In this embodiment as well, each ultrasonic transducer 52, 54 is associated with a sensor board 84, 86, which is contacted with the flexible PCB 56. A signal and power connection is then made via the PCB to a connector 144, indicated in Figure 18, which is then plugged into a connector on the main PCB side. In this concept, the lines 142a, 142b are replaced by the flexible PCB 56.

[0116] Alternatively, the signal connection of the ultrasonic transducers 52, 54 to the main PCB 10 or the metering board can also be made by wire bonding or via a printed circuit, the latter of which can, for example, be contained in an externally closed structure.

[0117] Figures 19 and 20 show examples of how the battery 8 can be connected to the main PCB 10 or another interface.

[0118] One simple option is to connect the battery 8 to the PCB via a plug connection, similar to the ultrasonic transducers 52, 54 shown in Figure 17 - however, such a solution requires additional installation space in the control housing 4.

[0119] In the embodiment shown in Figure 19, the battery 8 is supported on the battery holder base 64, which was inserted into the control housing 4 in a previous assembly step. The main PCB 10 and the EDU 12, which is connected to it for power and signal transmission, are equipped with spring contacts 148a, 148b, which, as shown in Figure 19, project from the main PCB 10 towards the battery 8. During assembly, the main PCB 10, with the EDU 12 connected to it, is moved vertically (see arrow in Figure 19) towards the battery 8, so that the spring contacts 148a, 148b come into contact with the terminals of the battery 8 and thus establish the electrical connection. This design enables extremely simple assembly with minimal manufacturing effort for the spring contacts 148a, 148b.

[0120] In the embodiment shown in Figure 20, the main PCB 10 and the EDU 12 are equipped with the contact tabs 90a, 90b already described with reference to Figure 3. These tabs also project from the underside of the main PCB 10 towards the battery 8 and are soldered to it. For optimal connection, these contact tabs 90a, 90b can also extend through the main PCB 10. As explained above, the cover glass 14 is connected to the annular end face of the control housing 4 via a seal. Figure 21 shows a variant in which this seal is first applied as a plastic compound to the cover glass 14 or the control housing 4 and then hardens. Such a sealant thus also acts as an adhesive bond, ensuring a reliable seal and connection between the cover glass 14 and the control housing 4 after hardening.

[0121] Figure 22 shows a variant in which a sealing recess 150 is provided along the annular end face of the control housing 4, into which a seal 152 is inserted, for example, by two-component injection molding. In principle, however, such a seal 152 can also be inserted into the sealing recess 150 in a separate assembly process. Positioning elements, designated by reference numeral 154, support the positioning of the seal 152 within the sealing recess 150. The positioning element 154 can, for example, be formed by a plurality of projections, each of which engages in a recess 156 of the control housing 4.

[0122] In the sectional view according to Figure 23, the cover glass 14 is shown, which is placed on the control housing 4, with the seal 152 being designed according to the variants in Figures 21 and 22. In the illustrated embodiment, the seal 152, similar to the embodiment according to Figure 22, dips into a sealing recess 150. The final positioning of the cover glass 14 is then achieved – as explained – by placing the sealing frame 17 on it, which is welded, for example, by ultrasonic welding to a shoulder 158, so that the weld seam 162 extends along the bearing area of ​​a leg 160 of the sealing frame 17 on the shoulder 158. A lip 164 of the sealing frame 17 rests on the cover glass 14 with preload.

[0123] Figure 24 shows a variant of the embodiment according to Figure 23, in which the sealing frame 17 is not materially bonded but force- and form-fitted to the GW0516P-WQ-0019

[0124] - 28 -

[0125] The control housing 4 is connected. For this purpose, a leg profile 166 is formed on the inside of the leg 160 and a counter profile 168 is formed on the shoulder side (control housing 4) such that the sealing frame 17 is brought into a detent position by suitable displacement and force application, in which the two profiles 166, 168 engage each other forcefully and form-fittingly, so that the lip 164 rests on the cover glass 14 with the required preload.

[0126] Figure 25 shows a variant in which the sealing frame 17 is connected to the control housing 4 via a fusible seal, wherein in this embodiment according to Figure 25 a quality seal, for example a MID seal (Measuring Instruments Directive) 172, is fused on by means of a stamp 171. This MID seal 172 can of course be applied to all embodiments.

[0127] Figure 26 shows a similar variant in which sealing is achieved by laser welding, whereby a MID seal 172 can also be applied as a quality mark by suitable guidance of the laser or via the stamp 172. In both the formation of a fusible link and laser welding, it is advantageous if the sealing frame 17 is made of approximately the same material as the control housing 4, for example, PPS.

[0128] Figures 27a, 27b, and 27c illustrate different possibilities for positioning desiccant within the control housing 4. Figure 27 shows one variant in which a holder 174 is provided for the desiccant, which is positioned at a suitable location within the control housing 4, so that a bag 173 containing desiccant can be inserted from above.

[0129] According to Figure 27b, such a holder 174 can also be provided in the area of ​​the battery holder base 64.

[0130] In an embodiment with very low equipment complexity, as shown in Figure 27c, the desiccant is filled directly into a suitable desiccant receptacle 176. Figure 28 illustrates a concept in which the main PCB 10 and the communication module 76 are divided into three components. Figure 28 shows the two ultrasonic transducers 52, 54 and their sensor boards 84, 86, which are fixed in position by the fixing pins 83 and are contacted with the control electronics as described above. In the illustrated embodiment, the two ultrasonic transducers 52, 54 are contacted with a dedicated metering board 178, also called a MET board, whose control circuitry is specifically designed for algorithm-based evaluation of the measurement signals. The user interface and power management are handled by a dedicated UL board 180, which also controls the EDU 12.The third element of this board arrangement is the communication module 76, which is optimized for communication with a base station or similar device. In this way, each part of the electronic circuit (metering board 178, UL board 180, and communication module 76) is optimally adapted to its respective requirements, ensuring high measurement accuracy and efficiency of the flow meter 1.

[0131] The assembly of a flow meter 1 designed according to the preceding descriptions is briefly explained with reference to Figures 29 to 44.

[0132] As described above, an ultrasonic transducer base body 2 is initially provided, which is designed with the same geometry for all installation lengths LL of a nominal diameter DN. If a flow meter 1 with a comparatively large installation length LL is required, corresponding pipe sections 22, 24 are attached to the inlet nozzle 18 and the outlet nozzle 20, respectively, as shown in Figure 29. For example, the pipe sections 22, 24 can be cooled to a temperature of -68°C using CO2 and then inserted into the nozzles 18, 20. Threaded fittings 26, 28 are then attached to the outer end sections of the pipe sections 22, 24 in the same manner, thus forming the basis for a flow meter 1 with the corresponding installation length LL and nominal diameter DN.For relatively short overall lengths, the two threaded fittings 26, 28 are attached directly to the base body 2 according to Figure 30, whereby the threaded fittings 26, 28 are then cooled in a corresponding manner so that the connection is made via a press fit.

[0133] As explained above, the basic concept of the control housing 4 shown in Figure 31, with its integrated control electronics, can be used for virtually all nominal diameters DN and installation lengths LL, with the variation of the nominal diameter DN essentially being achieved by selecting the appropriate measuring channel base 46 (see Figure 6). According to Figure 8, the measuring channel base 46 and the measuring channel roof 44 are connected to each other, preferably welded together, according to the required nominal diameter DN.

[0134] In a step shown in Figure 32, the two ultrasonic transducers 52, 54 with their sensor boards 84, 86 with, for example, the flexible PCB 56 and the connector 58 are then fixed in the bottom area of ​​the control housing 4, wherein the connector 58 is arranged in a suitable connector holder 182.

[0135] As shown in Figure 33, in a further assembly step a seal 184 is inserted into the body interface 30 which encompasses the radial recess 48, and the one-piece control housing 4 is inserted as shown in Figure 32, so that the measuring channel insert 80 is immersed in the channel of the base body 2. The two inserts 40, 42 (not shown in Figure 33) can also be inserted axially in a corresponding manner.

[0136] After the electronics housing 4 (control housing) is placed on the base, the two cheeks 34a, 34b engage the side cheeks 108a, 108b (see Figure 34), so that the openings 94 or recesses 110 formed therein are aligned with each other and the tangential bolts 36 or the two bolt bodies 134 can be attached on both sides to connect the control housing 4 to the base body 2. In a further step (Figure 35), the protective covers 128 are then applied to prevent the bolts 36 from loosening and to protect them.

[0137] In a parallel manufacturing step, as shown in Figure 36, the battery 8 is contacted in the manner described above, for example via the contact tabs 90a, 90b with the main PCB 10 and the EDU 12.

[0138] The battery holder base 64 is then inserted into the upwardly open control housing 4 - as shown in Figure 37 - and is fixed in position by the spring tongues 67, with the pins 68 pointing towards the viewer in the illustration according to Figure 37.

[0139] Subsequently, as shown in Figure 38, the unit assembled according to Figure 36 with the battery 8, the main PCB 10 and the EDU 12 is placed on the battery holder base 64 and connected to the ultrasonic transducers 52, 54 via a plug connection not shown.

[0140] For position fixing, as shown in Fig. 39, the battery holder upper part 72 is inserted vertically into the control housing 4, which in turn engages the undercuts 88 via spring clips 74a, 74b, so that a reliable positional positioning of the main PCB 10 and battery 8 within the control housing 4 is ensured.

[0141] According to the assembly step shown in Figure 40, the communication module 76 is then placed on support elements of the battery holder upper part 72 and simultaneously contacted with the main PCB 10.

[0142] The ID plate 16 is then placed vertically, its window 70 revealing the EDU 12 (display) (Figure 41).

[0143] As explained above, the cover glass 14 is then applied to this ID plate 16 or to the ring end face of the control housing 4, wherein, for example, the seal 152 is applied as a sealant to the circumferential area of ​​the cover glass 14 and this is then placed vertically onto the control housing 4 (Figure 43).

[0144] In a further assembly step, the sealing frame 17 is then attached, which is connected to the control housing 4 by force or form locking and presses the cover glass 14 into its target position - the flow meter 1 is now ready for the first test run.

[0145] Figures 45a to 45d illustrate an embodiment in which the measuring channel insert 80 and the reflectors 50a, 50b, 50c are combined to form a compact measuring channel module 186, to which the two ultrasonic transducers 52, 54 are also mounted. This measuring channel module 186 can then be pre-assembled and tested separately from the other components, i.e., the control housing 4, the base body 2, the two pipe sections 22, 24, and the threaded fittings 26, 28, with the essential components of the flow meter 1 being compactly combined. This measuring channel module 186, in particular the measuring channel insert 80, can consist of several components that are then joined, mounted, ultrasonically welded, or otherwise assembled to produce the compact measuring channel module 186. In principle, the measuring channel module 186 or the measuring channel 80 can also be manufactured as a monolithic component.

[0146] In the illustrated embodiment, the control housing 4 and the base body 2 are of monolithic or one-piece construction, whereby, depending on the overall length LL, the pipe sections 22, 24 with the threaded fittings 26, 28 can be attached (see dashed lines in Figure 45a) and connected to the base body 2 / control housing 4, for example, by ultrasonic welding or the like. An alternative variant is also shown in which the pipe sections 22, 24 with the fittings 26, 28 are formed one-piece with the housing 4 and the base body 2.

[0147] Further details of this concept can be seen in Figures 45b to 45d. Figure 45b shows a three-dimensional view of the measuring channel module 186, which, as mentioned above, can consist of several interconnected components that are not explicitly shown in Figure 45b. This measuring channel module 186 has a module web 188 forming the measuring channel 82, through which the measuring channel 82 is formed with the profile described above. Accordingly, the three reflectors 50a, 50b, 50c are integrated into the module web 188 or the measuring channel insert 80, which are not visible per se in the representation according to Figure 45b. Receptacles for the reflectors 50a, 50b, 50c, opening into the wall of the module web 188, are shown there.

[0148] The control housing-side roof section of the module web 188 is formed by a module cover surface 190, on which two support wedges 192, 194 for the two ultrasonic transducers 52, 54 are formed. As in the embodiment described with reference to Figure 3, two fixing pins are arranged on each of these support wedges 192, 194, by means of which the sensor board 84, 86 is fixed in position. The inclination of the two support wedges 192, 194 and the reflectors 50a, 50b, 50c attached to them, as well as their positioning, is such that the described W-shaped signal path (see Figure 7) is established.

[0149] A module flange 196 is formed at the upper end section of the module web 188. This flange encompasses the ultrasonic transducers 52, 54 and, in the assembled state, rests with its bearing surface 198 on the base 32 of the control housing 4. For positioning on the control housing 4 or on the base body 2, three adjacent fixing pins 200a, 200b, 200c are formed on the module flange 196. These pins project vertically (view according to Figure 45b) and engage in corresponding locking recesses 202a, 202b, 202c in the base 32 of the control housing 4 (see Figure 45d).

[0150] In the illustrated embodiment, as shown in Figures 45c and 45d, the base body 2 and the control housing 4 are manufactured as a monolithic structure, preferably by injection molding. The two previously described pipe sections 22 and 24 with the two fittings 26 and 28 are then inserted into the base body 2 to the required lengths and subsequently bonded to the base body 2. GW0516P-WQ-0019

[0151] - 34 - connected, so that practically any construction length LL and nominal diameter DN can be easily realized.

[0152] In the illustration according to Figure 45d, the base 32 with the radial recess 48 is shown, through which the measuring channel module 186 described above is inserted, with the three fixing pins 200a, 200b, 200c engaging in the locking recesses 202a, 202b, 202c provided on the base 32 of the control housing 4. The fixing pins 200a, 200b, 200c and the locking recesses 202a, 202b, 202c can be jammed together, press-fitted, and / or materially bonded, e.g., by ultrasonic welding. In principle, it is also possible to connect the entire module flange 196 to the base 32 of the control housing 4 by ultrasonic welding. This illustration also shows the longitudinal channel of the base body 2, into which the module web 188 of the measuring channel module 186 is inserted, so that the measuring channel 82, which is open to the pipe sections 22, 24, is aligned towards the flow cross-sections of the pipe sections 22, 24.The radial recess 48 is then covered / closed by the module flange 196.

[0153] Such a concept makes it possible to manufacture the measuring channel module 186 very precisely, since it contains all the components essential for the measuring process. A method that meets somewhat lower quality requirements can then be used to manufacture the control housing 4 and the base body 2 preferably connected to it, so that, for example, different suppliers can be used for its production.

[0154] In the embodiments shown in Figures 1 to 44, the control housing 4 is connected to the base body 2 via bolts 36, these bolts 36 engaging in recesses 110 of the body interface 30. However, such a method of fixing the control housing 4 in position involves considerable manufacturing and assembly effort.

[0155] Figures 46a to 46c illustrate an embodiment in which the control housing 4 and the base body 2 are rusted. Figure 46a shows the control housing 4 and the base body 2 with the two pipe sections 22, 24 in their rusted state, with the base body 2 shown on top. Figure 46b shows the unrusted components of the flow meter 1 with the base body 2 and a portion of the measuring channel lower section 46 contained therein, which, together with the measuring channel roof 44 formed on the bottom 32 of the control housing 4, forms the measuring channel insert 80 that delimits the actual measuring channel 82 (see Figure 46c).

[0156] The corrosion process can be carried out in different ways. In the illustrated embodiment, two parallel locking grooves are provided on the outer circumferential wall of the base body 2, of which only one locking groove 204b is visible in the illustration according to Figure 46b. These locking grooves 204a, 204b (see also Figure 46c) each form a locking surface 206a, 206b (see also Figure 46c), which, in the corrosiond state, are engaged by locking cheeks 208a, 208b formed on the control housing 4. These extend along the base 32 at approximately a parallel distance to the measuring channel roof 44. In the illustrated embodiment, the end sections of the locking cheeks 208a, 208b on both sides are curved inwards according to the outer contour of the part of the base body 2 they engage, thus ensuring an optimal locking fit.The geometry of the locking jaws 208a, 208b is designed to ensure the elasticity required for the locking process and secure locking.

[0157] In the illustrated embodiment, each locking groove 204a, 204 is assigned a locking cover 210a, 210b, which covers the locking groove 204a, 204b and thus the entire corrosion.

[0158] This is further illustrated by Figure 46c, which shows a schematic longitudinal section transverse to the longitudinal axis of the flow meter 1, depicting only a portion of the control housing 4. As explained, the measuring channel roof 44 is formed on its base 32, which, together with the measuring channel lower part 46, forms the measuring channel insert 80, through which the approximately rectangular measuring channel 82 is formed in this embodiment. At a distance from the measuring channel roof 44, the two locking jaws 208a, 208b are provided on the base 32 of the control housing 4, each with a locking projection 212a, 212b at its free end sections, which, when rusted, engages the corresponding locking surface 206a, 206b on the base body 2. As explained above, this corrosion is then covered in the rusted state by the two locking covers 210a, 210b, so that accidental unlocking of the corrosion is virtually impossible.

[0159] In the illustration according to Figure 46c, a seal 214 is provided in the area of ​​the radial recess 42 of the base body 2, by means of which the control housing 4 is sealed against the measuring channel 82. Such a seal can also be provided in the previously described embodiments (see, for example, Figure 4).

[0160] Alternatively, the control housing 4 and the base body 2 can also be joined together by material bonding, e.g. by ultrasonic welding.

[0161] In all the embodiments described above, the reflectors 50a, 50b, 50c are manufactured as planar elements, for example made of metal, which are preferably fixed in position by overmolding in a measuring channel wall. In the embodiment according to Figure 47a, the reflector is formed by an insert body 216a, 216b, 216c, which is approximately bolt- or cylinder-shaped and is provided section by section with a reflector surface 218a, 218b, 218c. This insert body 216a, 216b, 216c is then inserted into a receptacle 220a, 220b, 220c, which are open towards the measuring channel 82. These receptacles 220a, 220b, 220c are formed in a suitable wall of the measuring channel 82. In the illustrated embodiment, the insert body 216b is arranged in the measuring channel roof 44 and the two insert bodies 216a, 216c are arranged in the measuring channel lower part 46.The geometry and position of the images 220a, 220b, 220c is adapted to the angle of attack of the W-shaped signal path, so that correct beam guidance is ensured.

[0162] In the illustrated embodiment, each receptacle 220a, 220b, 220c is designed as a blind hole, the diameter of which is adapted to that of the insert body 216. These receptacles 220a, 220b, 220c and the associated insert bodies 216a, 216b, 216c are designed in the illustrated embodiment such that the reflector surface 218a, 218b, 218c forms part of the roof surface 233 or the bottom surface 234 of the measuring channel 82, i.e., the receptacles 220a, 220b, 220c intersect the measuring channel 82 in such a way that the reflector surfaces 218a, 218b, 218c are aligned with respect to the bottom or roof surfaces 233, 234 of the measuring channel 82.

[0163] As can be seen in Figure 47a, in this embodiment the base surface 234 is also stepped according to the angle of attack of the reflector surfaces 218a, 218b, 218c.

[0164] The blind-shaped receptacles 220a, 220b, 220c can also be designed so that they do not intersect the measuring channel 82 and the optical connection to the measuring channel 82 is then made via a bore opening into the blind-shaped receptacle 220a, 220b, 220c (not shown), the axis of which is oriented perpendicular to the respective reflector surface 218a, 218b, 218c.

[0165] Further details of the construction of the insert bodies 216a, 216b, 216c are shown in Figures 47b, 47c.

[0166] As explained, each insert body 216 has an approximately bolt- or cylinder-shaped structure, with each end section having a seal 222 (only one of which is marked with a reference numeral) in the illustrated embodiment, each of which is received in a sealing groove 224. A reflector groove 226 is formed centrally between the sealing rings 222, the depth T of which corresponds approximately to half the diameter D of the insert body 216, so that the width B of the base surface forming the reflector surface 218 corresponds approximately to the diameter D of the insert body 216. The length L of the reflector groove 226 is then selected according to the required reflector base area. Of course, other geometries for the reflector groove 226 can also be implemented.In the illustrated embodiment of the insert body 216, the groove side surfaces 219, 221 each form a partial section of the measuring channel side wall adjacent to the reflector surfaces 218a, 218b, 218c (see Figures 47a, 47b), such that the length L corresponds to the measuring channel width. The end sections of the insert body 216, arranged on both sides of the reflector recess 226, are then received in the measuring channel side walls.

[0167] To fix the angular position of the insert body 216 within the respective receptacle 220a, 220b, 220c, a step is formed on an end face 228, which acts as an anti-rotation device 230. In the installed state, this anti-rotation device 230 engages positively with a correspondingly shaped projection of the receptacle 220a, 220b, 220c, thus preventing accidental rotation of the insert body 216 and ensuring the predetermined relative position of the reflector surface 218 within the measuring channel 82.

[0168] After inserting the insert body 216 into the blind-shaped receptacle 220, the opening of this receptacle is then closed by a sealing cap, which is inserted into the blind-shaped receptacle 220, for example by press fit, so that the insert body 216 is also fixed in its axial position.

[0169] Figure 48 shows a variant of the insert body 216 according to Figures 47b to 47c. This insert body 216 shown in Figure 48 has two parallel reflector surfaces 218, 218', each formed by a reflector groove 226, 226'. These are inserted into the bolt-shaped insert body 216 from opposite sides in the same axial region, leaving a separating web 232 between them. This results in two reflector surfaces 218, 218' oriented in opposite directions. Sealing rings 222 are provided at the end sections of the insert body 216 according to Figure 48, each section of which is received in a sealing groove 224. Otherwise, the embodiment according to Figure 48 corresponds to the embodiment described above, so further explanation is unnecessary. Figures 49a to 49c show a variant of the previously described embodiment of an insert body 216.In this embodiment, the reflector surface 218 is not configured as a diagonal or tangential surface, but rather on the end face of the insert body 216. This results in the insert body 216 being positioned with its longitudinal axis parallel or coaxial to the incident ultrasound signal, unlike in the previously described embodiment where its longitudinal axis is perpendicular to the signal. Consequently, as indicated in Figure 49a, the end face of the insert body 216, configured as a reflector surface 218 (see Figures 49b, 49c), can be positioned in a receptacle 220 formed in the base surface 234 or in a top surface (not shown) of the measuring channel insert 80. Due to the axial position of the reflector surface 218, the design of the receptacle 220 is simpler than in the previously described embodiments.

[0170] Figure 49b shows a section approximately perpendicular to the plane of the drawing in Figure 49a. This section shows that the insert body 216 is approximately helical in shape, with a threaded section 236 screwed into a corresponding threaded bore 238 in the receptacle 220 of the measuring channel insert 80. This threaded bore 238 is designed such that it opens into the measuring channel 82. In the illustrated embodiment, the threaded bore 238 is stepped back in the opening region to form a reflector window 240, which is aligned with respect to the signal path. Accordingly, the reflector surface 218 formed by the end face of the helical insert body 216 is partially covered by the reflector window 240.

[0171] The end section of the insert body 216, located away from the reflector surface 218, is formed by a head 242 that is radially extended relative to the threaded section 236 and has a suitable profile for engaging an insertion tool. A sealing groove 224 is formed on the outer circumference of this head 242, into which a sealing ring 222 is provided for sealing the measuring channel 82. This head 242 is formed in a corresponding radial extension 244 of the receptacle 220 that receives the insert body 216. The insertion depth of this insert body 216 is determined by the contact of the end face (reflector surface 218) with the circumferential walls of the reflector window 240 or by the contact of an annular end face 246 with a radial step 248 in the transition area to the threaded bore 238. The securing of this insert body 216 can in turn be achieved by inserting a sealing cap 250 with press fit into the receptacle 220 which receives the insert body 216.For this purpose, it can be designed, for example, with a cap receptacle 252 adjoining the radial extension 244.

[0172] The applicant reserves the right to direct separate independent patent claims to the insert bodies 216 with reflector surfaces designed as radial or tangential surfaces or as end faces.

[0173] A special feature of the concept according to the invention is that practically all components of the control electronics can be mounted in the vertical direction, i.e. in the direction from the cover glass 14, without complex tools or the like, automatically or manually, as shown in Figures 29 to 44, whereby, due to the very simple design of the flow meter 1, it can be made compact and sufficient space remains for the various components.

[0174] The described body interface 30 enables precise positioning of the control housing 4 on the base body 2 with extremely small space requirements. A further advantage of this concept according to the invention compared to conventional solutions is that the connection of the control housing 4 to the body interface 30 of the base body 2 takes place in an area that is closer to the pressurized zones of the flow meter 1 than is the case in the prior art, thus reducing deformation at high pressures.

[0175] Another advantage of the concept according to the invention is that practically any installation length LL can be realized through the modular design with the base body 2, the pipe sections 22, 24 and suitable threaded fittings 26, 28, which are preferably connected to each other by press fits, so that subsequent removal / modification is also possible without damaging the components.

[0176] As explained, the control housing 4 with the electronics incorporated therein can be used for practically any nominal diameter DN and installation length LL with minor modifications, the sensors and the reflectors 50 being inserted into the monolithic / one-piece control housing 4 regardless of the nominal diameter DN and the installation length LL in such a way that the same signal path characteristics 95 and harmonized channel characteristics result.

[0177] Furthermore, a concept is revealed in which a monolithically designed measuring channel module 186 is provided, into which the measuring channel insert 80 with the reflectors 52a, 52b, 52c is integrated and on which the ultrasonic transducers 50a, 50b, 50c are pre-mounted.

[0178] Another concept proposes to design the reflectors 52a, 52b, 52c as screw-, bolt- or cylindrical-shaped insert bodies 216 and to insert them into receptacles 200 open towards the measuring channel 82.

[0179] Revealbart is a flow meter that can be manufactured with minimal equipment effort in different nominal diameters DN and installation lengths LL.

[0180] Reference symbol list

[0181] 1 flow meter

[0182] 2 Flow channel base bodies

[0183] 4 control housings

[0184] 6 Control electronics

[0185] 8 batteries

[0186] 10 main PCBs

[0187] 12 EDU

[0188] 14 Cover glass

[0189] 16 ID plate

[0190] 17 sealing frames

[0191] 18 inlet nozzles

[0192] 20 outlet nozzles

[0193] 22 pipe sections

[0194] 24 pipe sections

[0195] 26 threaded fittings

[0196] 28 threaded fittings

[0197] 30 Bodyinterface

[0198] 32 Floor

[0199] 34 Cheek

[0200] 36 tangential bolts

[0201] 38 bolt plate

[0202] 40 inlet inserts

[0203] 42 Outlet insert

[0204] 44 Measuring channel roof

[0205] 46 Measuring channel lower part

[0206] 48 Radial recess

[0207] 50 reflector

[0208] 52 ultrasound transducers

[0209] 54 ultrasound transducers

[0210] 56 flexible PCB

[0211] 58 plugs 60 plug part

[0212] 62 Seal

[0213] 64 Battery holder base

[0214] 66 Exclusion

[0215] 67 Spring tongue

[0216] 68-pin

[0217] 70 windows

[0218] 72 Battery holder top

[0219] 74 spring clips

[0220] 75 Support leg

[0221] 76 Communication module

[0222] 78 demotion

[0223] 80 measuring channel insert

[0224] 82 measuring channels

[0225] 83 Fixing pin

[0226] 84 Sensor board

[0227] 86 Sensor board

[0228] 88 Undercut

[0229] 90 contact flag

[0230] 92 Undercut

[0231] 93 Housing bodies

[0232] 94 Breakthrough

[0233] 95 Signal path characteristics

[0234] 96 weld seam

[0235] 98 Sliding groove

[0236] 100 fixing projection

[0237] 102 Investment area

[0238] 104 slots

[0239] 106 clamping profile

[0240] 108 Side cheek

[0241] 110 Exclusion

[0242] 111 Base body wall

[0243] 112 Radial extension 114 Passing advantage

[0244] 116 Passport exemption

[0245] 118 Pass area

[0246] 120 radial expansion

[0247] 122 downgraded final section

[0248] 124 Support ring area

[0249] 126 Check valve

[0250] 128 Protective cover

[0251] 130 Exclusion

[0252] 132 clamping rib

[0253] 134 bolt bodies

[0254] 136 Framework structure

[0255] 138 Fasteners

[0256] 140 fasteners

[0257] 142 Management

[0258] 144 plugs

[0259] 148 Spring contact

[0260] 150 sealing recess

[0261] 152 Seal

[0262] 154 Positioning element

[0263] 156 Exclusion

[0264] 158 shoulder

[0265] 160 thighs

[0266] 162 weld seam

[0267] 164 Lippe

[0268] 166 Leg profiling

[0269] 168 Counter-profile

[0270] 170 Hot melt seal

[0271] 171 stamps

[0272] 172 MID seals

[0273] 173 bags

[0274] 174 holders

[0275] 176 Desiccant absorption 178 Metering board

[0276] 180 UL board

[0277] 182 Plug holder

[0278] 184 Sealing ring

[0279] 186 Measurement channel module

[0280] 188 modular bridge

[0281] 190 module deck area

[0282] 192 support wedge

[0283] 194 support wedge

[0284] 196 module flange

[0285] 198 contact area

[0286] 200 fixing pins

[0287] 202 Locking recess

[0288] 204 Rastnut

[0289] 206 rest area

[0290] 208 Rastwange

[0291] 210 Latch cover

[0292] 212 Rastvorsprung

[0293] 214 Seal

[0294] 216 deployment units

[0295] 218 Reflector area

[0296] 219 side area

[0297] 220 recording

[0298] 221 side surface

[0299] 222 Sealing ring

[0300] 224 Sealing groove

[0301] 226 Reflector groove

[0302] 228 Front surface

[0303] 230 Anti-rotation device

[0304] 232 dividing bridge

[0305] 233 roof area

[0306] 234 square meters of floor space

[0307] 236 Thread section 238 Threaded hole

[0308] 240 reflector windows

[0309] 242 heads

[0310] 244 Radial expansion

[0311] 246 Ring face 248 Radial step

[0312] 250 sealing caps

[0313] 252 cap holder

Claims

AMENDED CLAIMS received by the International Bureau on 8 May 2026 (08.05.2026) 1. Flow meter (1) with a flow channel base body (2) attachable to a pipeline, on which a measuring unit is held, which has at least two spaced-apart sensors, preferably ultrasonic transducers (52, 54), whose measuring signals can be coupled into a measuring channel (82) and coupled out via reflectors (50), and with control electronics (6) housed in a control housing (4) for controlling the sensors and for processing the measuring signals, wherein the measuring channel (82) is formed at least sectionally by a measuring channel insert (80) which is inserted into the base body (2) through a radial recess (48) and is connected to a fluid inlet (40) arranged upstream or downstream of the base body (2).Fluid outlet (42), characterized in that the fluid inlet (40) and the fluid outlet (42) are attached to the base body (2) as separate components and are connected to it by force or material bonding, wherein the fluid inlet (40) and the fluid outlet (42) each have a fitting for connection to the pipeline, wherein pipe sections (22, 24) are provided between the fittings and the base body (2) for adjusting the installation length (LL).

2. Flow meter (1) according to claim 1, wherein the fittings are threaded fittings (26, 28).

3. Flow meter (1 ) according to claim 1 or 2, wherein the base body (2) is designed such that it can be used for different installation lengths (LL) at a nominal diameter (DN).

4. Flow meter (1 ) according to the preamble of claim 1 or according to one of the preceding claims, wherein the control housing (4) is designed such that the sensors and the components of the control electronics (6) including the power supply, in particular battery (8), their holders, covers and other functional components, can be inserted into the control housing (4) in a vertical direction, i.e. transverse to the measuring channel axis, and can be fixed in position. AMENDED SHEET (ARTICLE 19) 5. Flow meter (1 ) according to one of the preceding claims, wherein the control housing (4) and the measuring channel insert (80) are formed monolithically or as a one-piece structure made of materially bonded components.

6. Flow meter (1 ) according to claim 5, wherein the control housing (4) with the measuring channel insert (80) is connected to a body interface (30) of the base body (2) via tangential bolts (36), wherein lateral fixing cheeks (34) on a base (32) of the control housing (4) encompass the body interface (30) on both sides.

7. Flow meter (1 ) according to claim 6, wherein several tangential bolts (36) are formed on a bolt body (134).

8. Flow meter (1 ) according to claim 6 or 7, wherein the tangential bolts (36) or the bolt body (134) are secured by means of a protective cover (128).

9. Flow meter (1 ) according to one of the preceding claims, wherein a cover glass (14) is attached to the control housing (4) via a seal (152), wherein the seal (152) is applied to the cover glass (14) or the control housing (4) or is integrated into a sealing recess (150) of the control housing (4).

10. Flow meter (1 ) according to claim 9, wherein the control housing (4) and the cover glass (14) are connected / sealed by means of a one-piece sealing frame (17), wherein the sealing frame (17) is preferably connected to the control housing (4) by ultrasonic or laser welding or by snapping.

11. Flow meter (1 ) according to claim 9 or 10, wherein a MID seal (172) is applied thermally or by plastic deformation in a butt joint area between sealing frame (17) and control housing (4). AMENDED SHEET (ARTICLE 19) 12. Flow meter (1 ) according to the preamble of claim 1 or according to one of the preceding claims, wherein the control electronics (6) is designed with a metering board (178), a UL board (180) and a communication module (76) which are mounted in the control housing (4) offset in the vertical direction.

13. Flow meter (1) according to one of the preceding claims, wherein the base body (2) is designed such that, for different nominal diameters (DN), the sensor spacing, reflector spacing, sensor angle of inclination and sensor-reflector distance in the direction of flow remain essentially the same.

14. Flow meter (1 ) according to claim 13, wherein a geometry of a control housing-side measuring channel roof (44) with sensor positioning, reflector position is the same for several nominal diameters (DN) and installation lengths (LL).

15. Flow meter (1 ) according to one of the preceding claims, wherein a battery holder is designed in two parts with a battery holder lower part (64) and a battery holder upper part (72), which are inserted into the control housing (4) by means of force-fit and / or form-fit, preferably via undercuts (88, 92) engaging spring elements.

16. Flow meter (1) according to one of the preceding claims, wherein a battery (8) is contacted with a main PCB (10) or the like via a plug connection, by soldering or via spring contacts (148).

17. Flow meter (1 ) according to one of the preceding claims, wherein the control housing (4) is essentially the same for all nominal diameter (DN) and installation length (LL) combinations, wherein adaptation to different nominal diameters (DN) is achieved by replacing a measuring channel lower part (46).

18. Flow meter (1) according to one of the preceding claims, wherein at least one reflector (50) is designed as an insert body (216) which is inserted into a receptacle (220) of a measuring channel wall open towards the measuring channel (82). AMENDED SHEET (ARTICLE 19) and a reflector surface (218) is formed on the outer circumference or end face (228) of which the dimensions are adapted to those of the measuring channel (82).

19. Flow meter (1 ) according to claim 18, wherein the insert body (216) is formed approximately bolt-, screw- or cylindrical-shaped, wherein the reflector surface (218) is formed on an end face or a tangential surface (228), wherein preferably at least one reflector sealing ring (222) is provided on the outer circumference at a distance from the reflector surface (218).

20. Flow meter (1) according to one of the preceding claims, comprising a measuring channel module (186) forming the measuring channel insert (80), which is monolithic or formed from several parts connected to each other by force, material and / or form-fitting, wherein the reflectors (50) and fastening means for fixing in the base body (2) are integrated and the sensors are mounted and preferably the outer contour is designed for inserting and fixing the position of the pre-assembled measuring channel module (186) through the radial recess (48) into a longitudinal channel of the base body (2) which is preferably formed integrally with the control housing (4). AMENDED SHEET (ARTICLE 19)

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