Flow Meter Rotor Assembly Using Thermally Diffused Metallic Material
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Solution Overview
Problem
Flow meters with turbine rotors face issues of erosion and brittleness due to debris-laden fluids, leading to rotor breakage and slipping, which existing technologies fail to adequately address.
Innovation Solution
A rotor assembly made from a thermally diffused metallic material, such as a steel alloy, is used, which is hardened through a thermal chemical diffusion process to enhance erosion and corrosion resistance, and is integral with the shaft to prevent slipping, utilizing additive manufacturing for construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a tungsten carbide shaft is machine pressed through the rotor, then erosion resistance is improved, but the shaft becomes brittle and prone to breaking
Solution Approach 1:
The patent applies composite materials by combining tungsten carbide particles with a steel alloy matrix through thermal chemical diffusion. This creates a composite structure where the tungsten carbide provides erosion resistance while the steel alloy provides ductility and toughness, eliminating the brittleness issue of solid tungsten carbide shafts.
Solution Approach 2:
The patent changes the physical and chemical parameters of the steel alloy shaft through thermal chemical diffusion process. The shaft is heated to allow carbon and other elements to diffuse into the steel alloy, changing its microstructure and properties to achieve both erosion resistance and maintained ductility.
2Object-affected harmful factors
If a machine pressed rotor is used, then erosion resistance is improved, but the rotor weakens and slips free of the shaft
Solution Approach 1:
The patent merges the rotor and shaft into a single integral structure using additive manufacturing. This eliminates the interface between separate rotor and shaft components, preventing slipping while maintaining erosion resistance through the thermally diffused metallic material.
Solution Approach 2:
The patent replaces the mechanical assembly process (machine pressing) with additive manufacturing technology. This creates an integral rotor-shaft structure without mechanical interfaces, eliminating the slipping problem while maintaining the desired erosion resistance properties.
3Manufacturing precision
If traditional manufacturing methods are used, then production time is extended, but manufacturing precision can be maintained
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods with additive manufacturing technology. This substitution enables complex geometries to be built directly layer-by-layer, significantly reducing production time while maintaining or improving manufacturing precision through digital control of the additive process.
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
The solution provides a rotor assembly that is resistant to erosion, corrosion, and cracking, maintaining ductility and ensuring reliable operation in debris-laden fluids, while also reducing production time through advanced manufacturing techniques.
Implementation Method 1
the shaft 111 is made from a thermally diffused metallic material that is hardened and resistant to erosion, corrosion, and cracking
Implementation Method 2
a steel alloy shaft hardened using a thermal chemical diffusion process
Implementation Method 3
Flowing fluid through the flow path interacts with the rotor and causes the rotor to rotate
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A flow meter for determining a flow rate of a fluid. The flow meter includes a housing comprising a flow bore, a rotor assembly rotatable by the flow of fluid within the flow bore and comprising a thermally diffused metallic material, and a sensor unit configured to generate a signal indicative of a rotational rate of the rotor assembly.