Flow Rectifier Press-Fit Connection Without Welding Deformation
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Solution Overview
Problem
The existing methods for connecting flow rectifiers to measuring tubes, such as welding, are costly and prone to errors, especially for tubes with small nominal widths or thin walls, leading to potential deformations or defects.
Innovation Solution
A process connection that uses a base body with a recess to securely fasten a flow rectifier through press fitting by plastic deformation, creating a friction-locked connection that prevents the flow rectifier from dislodging without deforming the base body or the flow rectifier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding method is used to connect flow rectifier to measuring tube, then connection strength is improved, but manufacturing cost increases and risk of deformations/defects increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a press-fitting process (mechanical system). The flow rectifier is secured through plastic deformation of the base body material around the recess, creating a form-locked connection without requiring welding operations. This substitution eliminates welding costs, equipment requirements, and associated quality control complexities while maintaining connection integrity.
2Strength
If welding method is used to connect flow rectifier to measuring tube, then connection strength is improved, but risk of deformations and defects increases
Solution Approach 1:
The patent replaces welding with press-fitting to eliminate thermal processes that cause deformations and defects. The mechanical press-fitting process with plastic deformation avoids the high temperatures and localized stress concentrations of welding, thereby preventing welding seam defects such as cracks, cavities, and thermal distortions while maintaining secure connection.
Solution Approach 2:
The patent changes the connection mechanism from thermal-welding parameters to mechanical-pressing parameters. By controlling the press-fitting force and deformation degree, the process achieves reliable connection without the harmful thermal effects of welding, thus improving reliability by eliminating temperature-related defects.
3Ease of manufacture
If press fitting with plastic deformation is used to fasten flow rectifier, then manufacturing cost decreases and risk of deformations decreases, but connection strength may be reduced
Solution Approach 1:
The patent applies local quality by creating plastic deformation specifically in the edge region of the base body surrounding the recess, while keeping the rest of the base body and flow rectifier intact. This localized deformation concentrates the connection strength exactly where needed at the interface, providing sufficient holding force without requiring global structural reinforcement or excessive overall deformation.
Solution Approach 2:
The patent optimizes the press-fitting parameters by controlling the degree of plastic deformation to achieve adequate friction lock without over-deformation. By carefully selecting the pressing force and deformation extent, the process maintains connection strength sufficient for application requirements while avoiding the weaknesses associated with excessive deformation.
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 method enables a non-destructive, cost-effective, and reliable connection of the flow rectifier to the measuring tube, reducing the risk of deformations and defects, while ensuring a stable and secure attachment.
Implementation Method 1
fixed in place, e.g., by press fitting, using plastic deformation of an edge region of the base body surrounding the first recess
Implementation Method 2
creating a friction-locked connection that prevents the flow rectifier from dislodging
Data Source
AI summary
The present disclosure relates to a process connection for connecting a flow measuring device, to a pipeline, the process connection including a base body having an opening for conducting a medium and a flow rectifier, wherein the flow rectifier is inserted into a first recess of the base body and fixed in place by plastic deformation of an edge region of the base body surrounding the first recess, for example, by press fitting.