Ultrasound Flow Meter Moulded Reflector Unit
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Solution Overview
Problem
Existing ultrasound flow meters have complex manufacturing processes and require multiple components, leading to high costs, long production times, and increased chances of malfunction due to the complexity of assembling and positioning reflector units.
Innovation Solution
A method for manufacturing an ultrasound flow meter that integrates the reflector unit and reflector holder into a single moulded element, allowing for precise control of the reflector position and reducing the number of components, using materials like polymeric materials or stainless steel, and incorporating post-processing techniques to enhance acoustic impedance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate reflector parts and holder parts are preassembled before insertion, then the reflector unit can be positioned correctly, but the manufacturing complexity and number of components increase
Solution Approach 1:
The reflector and holder are merged into a single integrated reflector unit that is molded as one piece. This eliminates the need for separate reflector parts and holder parts, reducing the number of components while maintaining positioning precision through the integrated design.
Solution Approach 2:
The integrated reflector unit serves multiple functions simultaneously: it provides the reflective surface for ultrasound signals, acts as a holder for positioning, and functions as a flow-guiding element. This multi-functionality reduces the overall component count while maintaining all necessary functions.
2Manufacturing precision
If multiple manufacturing steps are used for preparing and inserting the reflector unit, then the reflector can be precisely manufactured, but the production time and costs increase
Solution Approach 1:
The manufacturing process merges multiple steps into a single injection molding operation. The reflector unit is molded directly in its final position within the housing, eliminating separate manufacturing and assembly steps while maintaining precision through the molding process itself.
Solution Approach 2:
The reflector unit is pre-positioned and fixed in its final location during the injection molding process. This preliminary positioning action eliminates the need for subsequent assembly steps, as the reflector is already in its correct position when the housing is molded around it.
3Adaptability or versatility
If more components are used in the flow meter, then the functionality can be enhanced, but the chances of malfunction increase
Solution Approach 1:
By merging the reflector and holder into a single integrated unit, the number of potential failure points is reduced. Fewer separate components mean fewer interfaces and connections that could malfunction, thereby improving reliability while maintaining all necessary functions.
4Manufacturing precision
If a complex shaped reflector holder geometry is used, then the reflector positioning and flow minimization are improved, but the manufacturing complexity increases
Solution Approach 1:
The complex geometry is integrated directly into the housing mold rather than requiring a separate reflector holder component. The housing itself is molded with the precise geometric features needed for positioning, eliminating the need for a separate complex-shaped holder while maintaining positioning accuracy.
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 approach simplifies manufacturing, reduces costs and timeframes, increases precision, and enhances the reliability of the flow meter by minimizing potential malfunctions and allowing for more precise flow measurement due to fewer components and improved acoustic performance.
Implementation Method 1
the ultrasound signals are guided on a path which is not along a direct line between the sending and receiving ultrasound transducer, but instead travel along a piecewise linear path where the direction is altered by at least one reflection along the way. This requires at least one reflective surface which reflects the ultrasound signals upon incidence
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3B
AI summary
A method for manufacturing an ultrasound flow meter, the method comprises forming a reflector unit 604, 606 as a single element comprising a reflector 612, 614 and a reflector holder 616, 618 in a moulding process, such as an injection moulding process using polymer. The reflectors are arranged to reflect ultrasound signals. The method further comprises mounting first and second ultrasound transducers in relation to the reflector unit 604, 606 and in relation to a measuring tube 602, 624 such that the one or more reflectors 612, 614 are arranged to reflect an ultrasound signal between the first and second ultrasound transducers. In a specific embodiment of the invention, the reflector units 604, 606 are integrated with the measuring tube or parts thereof 602, 624, the integration of parts simplifies the production and enhances performance of the finished ultrasound flow meter.