Flange Retention via Grooved Sensor Assembly and Clamping
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Solution Overview
Problem
Existing fluid meters face challenges in achieving reliable connections between components due to thermal expansion issues, especially when using materials with different coefficients of thermal expansion, which can lead to manufacturing problems and premature failure of joints during high-temperature welding or brazing processes.
Innovation Solution
A sensor assembly with a circumferential groove and retaining components that are clamped together using threaded mechanical fasteners, allowing for secure retention of a flange without direct welding or brazing, thereby accommodating materials with different thermal expansion coefficients and preventing accidental slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or brazing is used to join components with different materials, then strong connections are achieved, but thermal expansion differences cause joint failure and manufacturing problems
Solution Approach 1:
The connection system is divided into separate components: a flange, a retaining component with clamping force, and threaded mechanical fasteners. This segmentation allows each component to be optimized for its specific function while accommodating thermal expansion differences between dissimilar materials without causing joint failure.
Solution Approach 2:
The retaining component acts as an intermediary between the flange and the mechanical fasteners, distributing the clamping force and providing a compliant interface that accommodates thermal expansion differences. This intermediary structure prevents direct stress transmission that would cause joint failure during temperature variations.
2Ease of manufacture
If dissimilar materials are used for different components, then cost is reduced, but thermal expansion differences create manufacturing problems and connection failures
Solution Approach 1:
The retaining component is designed with dynamic characteristics that allow it to flex and accommodate thermal expansion differences between dissimilar materials. This dynamic design maintains precise connection alignment during temperature variations while enabling the use of cost-effective material combinations.
Solution Approach 2:
The connection system uses adjustable parameters including threaded fastener tension and clamping force to compensate for thermal expansion differences. By changing these parameters, the system maintains manufacturing precision across varying temperature conditions while using dissimilar materials for cost efficiency.
3Ease of manufacture
If high temperature welding processes are used, then components are joined, but thermal expansion causes dimensional changes and connection failures
Solution Approach 1:
The patent replaces thermal joining processes (welding/brazing) with a mechanical fastening system using threaded fasteners and a retaining component. This substitution eliminates the high-temperature thermal expansion problem entirely, as the mechanical connection can be assembled at ambient temperature and maintains dimensional stability without thermal distortion.
4Reliability
If flanges are securely retained on the sensor assembly, then connection reliability is improved, but the assembly becomes more complex
Solution Approach 1:
The retaining component merges multiple functions into a single element: it provides the clamping interface for the flange, distributes the mechanical fastener load, and accommodates thermal expansion. This merging reduces the number of separate parts needed while maintaining connection reliability, thereby managing assembly complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a secure and adaptable method for retaining flanges on fluid meters, reducing the risk of joint failure and allowing for the use of cost-effective materials, while maintaining a stable connection even under extreme temperature variations.
Implementation Method 1
the sensor assembly further comprises one or more threaded mechanical fasteners engaging with fastener apertures formed in the two or more retaining components to removably couple the two or more retaining components to one another
Implementation Method 2
two or more retaining components removably coupled together and engaging the circumferential groove; wherein the two or more retaining components are clamped together around the circumferential groove
Data Source
Figure 1
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AI summary
A sensor assembly (5) for a fluid meter (100) is provided. The sensor assembly (5) comprises a sensor assembly body (6) and one or more circumferential grooves (303) formed in the sensor assembly body (6). Two or more retaining components (105, 106) are removably coupled together around at least one of the one or more circumferential grooves (303) with a portion of the two or more retaining components engaging the circumferential groove. A flange (104) is also provided that surrounds at least a portion of the sensor assembly body (6) and is retained around the sensor assembly body (6) by the first and second retaining components (105, 106).