Ultrasound Flow Meter Transducer Circuit Board Integration
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Solution Overview
Problem
Existing ultrasound flow meters require complete assembly before testing, leading to late revelation of defects and increased production costs, with complex wire handling and fragile connections contributing to reliability issues and increased tolerances.
Innovation Solution
Integration of ultrasound transducers and circuit boards with dual functionality for both mechanical and electrical connection, allowing for pre-assembly testing and reducing the number of components and connections, using methods like soldering or conductive glue for direct and permanent fixing and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasound transducers are connected to the circuit board using separate fixing means and connection wires, then the flow meter can be assembled, but the assembly process becomes complex and testing cannot be performed until complete assembly
Solution Approach 1:
The patent combines the fixing means and electrical connection into a single integrated component. The circuit board itself serves as both the mechanical support structure and the electrical connection medium, eliminating the need for separate fixing means and connection wires. This merging reduces device complexity while maintaining ease of manufacture.
Solution Approach 2:
The circuit board is given dual functionality: it serves both as the structural support for mounting ultrasound transducers and as the electrical connection medium. This multi-functionality eliminates the need for separate components, reducing overall device complexity while simplifying the manufacturing process.
2Reliability
If complete assembly is required before testing, then all components can be installed, but defects are revealed late in the manufacturing process wasting assembly time
Solution Approach 1:
The patent enables preliminary testing of the ultrasound transducer circuit board assembly before final integration into the complete flow meter. By making the transducer-circuit board assembly a testable unit independently, defects can be detected early in the manufacturing process, preventing waste of assembly time on defective units.
Solution Approach 2:
The flow meter is divided into separable modules, with the ultrasound transducer-circuit board assembly forming an independent testable unit. This segmentation allows the modular assembly to be tested separately before final integration, enabling early defect detection and reducing manufacturing time loss.
3Device complexity
If separate fixing means and connection wires are used, then connections can be made, but the number of parts increases and precision is reduced
Solution Approach 1:
By merging the fixing function and electrical connection function into the circuit board itself, the patent reduces the number of separate parts. This reduction in component count directly improves manufacturing precision by minimizing cumulative tolerances and reducing the complexity of precise alignment required during assembly.
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 enables early detection of defects, reduces production costs, enhances reliability, and allows for more precise and compact flow meter designs with fewer parts and connections, improving the flow meter's lifetime and handling in various applications.
Implementation Method 1
ultrasound flow meters for measuring the velocity of a fluid flow
Implementation Method 2
ultrasound transducer, in particular in the form of a monolithic body of piezo-electric material
Data Source
AI summary
An ultrasound flow meter unit arranged to measure a fluid flow rate with one or more ultrasound transducers (606), and a circuit board (602) with an electronic circuit arranged to operate the ultrasound transducer(s) (106, 306). The ultrasound transducer (606), e.g. in the form of a piezo-electric element, is mechanically fixed to the circuit board (602) by a first electrically conducting fixing means which additionally serve(s) to provide an electrical connection between an electrical terminal of the transducer (606) and the electronic circuit. Hereby a functional flow measurement unit (600) is provided which can be tested prior to assembly with a flow meter housing etc. Preferably, a set of ultrasound transducers (106, 306) are soldered directly onto electrically conducting paths (631) on a surface of the circuit board (602) being in electrical connection with the electronic circuit, e.g. in a single SMT mounting process together with mounting of all other electronic components on the circuit board (602). Through-going openings (630, 640) of the circuit board (602) in the vicinity of these conducting paths (631) serve to provide thermal elasticity. A metal clip soldered to the circuit board (602) may serve to electrically connect a second electrical terminal of the transducer (606) to the electronic circuit.