Flow Meter Sounder Head Stepped Side Wall Design
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Solution Overview
Problem
Existing sonic transducers for flow meters face challenges in handling, operational safety, suitability for automated mass production, and manufacturing costs, particularly when exposed to high pressure media.
Innovation Solution
A sonic head design featuring a metallic pot with a stepped side wall and closure part, incorporating a reinforcement plate and adhesive layers for enhanced mechanical stability and pressure resistance, along with a plastic main body for weight reduction and protection against external interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic housing is used to withstand high pressure loads, then pressure resistance is improved, but weight and production costs increase
Solution Approach 1:
The housing is divided into two parts: a lightweight plastic main body and a separate metallic reinforcement plate. The reinforcement plate is only applied to areas requiring high strength (front and rear walls), while side walls remain lightweight plastic. This segmentation allows the housing to achieve necessary pressure resistance without the weight and cost of a complete metallic construction.
2Strength
If a metallic housing is used to withstand high pressure loads, then pressure resistance is improved, but production costs increase
Solution Approach 1:
The housing is divided into two parts: a lightweight plastic main body and a separate metallic reinforcement plate. The reinforcement plate is only applied to areas requiring high strength (front and rear walls), while side walls remain lightweight plastic. This segmentation allows the housing to achieve necessary pressure resistance without the weight and cost of a complete metallic construction.
Solution Approach 2:
The housing combines plastic and metal materials to achieve optimal balance between cost and strength. The plastic main body provides lightweight construction and cost-effectiveness, while the metallic reinforcement plate provides localized high-strength support where pressure loads are most critical.
3Ease of manufacture
If an open housing with sealing film is used, then production costs are reduced, but pressure resistance deteriorates
Solution Approach 1:
The housing is divided into two parts: a lightweight plastic main body and a separate metallic reinforcement plate. The reinforcement plate is only applied to areas requiring high strength (front and rear walls), while side walls remain lightweight plastic. This segmentation allows the housing to achieve necessary pressure resistance without the weight and cost of a complete metallic construction.
Solution Approach 2:
The housing combines plastic and metal materials to achieve optimal balance between cost and strength. The plastic main body provides lightweight construction and cost-effectiveness, while the metallic reinforcement plate provides localized high-strength support where pressure loads are most critical.
4Reliability
If the transducer housing is designed for high pressure resistance, then operational safety is improved, but handling difficulty increases
Solution Approach 1:
The housing is divided into two parts: a lightweight plastic main body and a separate metallic reinforcement plate. The reinforcement plate is only applied to areas requiring high strength (front and rear walls), while side walls remain lightweight plastic. This segmentation allows the housing to achieve necessary pressure resistance without the weight and cost of a complete metallic construction.
Solution Approach 2:
The housing combines plastic and metal materials to achieve optimal balance between cost and strength. The plastic main body provides lightweight construction and cost-effectiveness, while the metallic reinforcement plate provides localized high-strength support where pressure loads are most critical.
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 design provides improved resistance to high pressure loads, ensures reliable operation, and facilitates cost-effective, automated manufacturing, while maintaining the acoustic functionality of the transducer.
Implementation Method 1
an electromechanical sound conversion element which is glued to an inside of the pot base
Implementation Method 2
The transducer according to the invention has a pot made of a metallic pot material with a pot side wall, a pot base to be scanned through and a pot opening opposite the pot base, an electromechanical sound conversion element which is glued to an inside of the pot base
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The transducer (1), which has a longitudinal axis (2), is designed for installation in the measuring tube of a flow meter for the sound-based measurement of the flow rate of a medium. It comprises a pot (3) made of a metallic material with a pot side wall (4), a pot base (5) through which sound is transmitted, and a pot opening (6) opposite the pot base (5). It also includes an electromechanical sound transducer element (9) bonded to the inner surface of the pot base (5), two electrical leads (14, 15) extending from the pot opening (6) for electrical contacting the electromechanical sound transducer element (9), and a sealing element (17) inserted into the pot (3) that closes the pot opening (6). The pot side wall (4) terminates at the level of the pot opening (6) in a bent pot rim section (8) that extends laterally away from the longitudinal axis (2).The pot side wall (4) has a pot step (7) and the closure part (17) has a closure part step (26) corresponding to the pot step (7) in a closure part side wall (25), wherein the pot step (7) and the closure part step (26) are directly adjacent to each other.