Magnetic Inductive Flowmeter Coil Holder Injection Molding
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Solution Overview
Problem
Existing magnetic-inductive flowmeters face challenges in assembly precision and effort due to the need for precise alignment and holding of partial magnet systems, which can result in metrological disadvantages such as increased magnetic resistance and reduced signal strength.
Innovation Solution
A method for producing a coil holder using an injection molding process with high-temperature-resistant plastics like PEEK, PPS, or PPA, where the coil holder is designed with engagement means for easy mounting on the measuring tube, and coil contacts are integrated to connect coils directly to a power supply, eliminating the need for separate coil wires and enhancing magnetic field consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If partial magnetic systems are joined and held together by curved segments, then the magnetic system can be assembled, but mounting precision and effort deteriorate
Solution Approach 1:
The patent merges the coil holder and mounting structure into a single integrated component manufactured by injection molding. This combines multiple functions (holding coils, providing mounting features, ensuring precision alignment) into one piece, eliminating the need for separate curved segments and improving both assembly ease and mounting precision.
Solution Approach 2:
The patent replaces the mechanical assembly of multiple curved segments with a monolithic injection-molded plastic component. This substitution eliminates complex mechanical joining requirements and achieves precise mounting through the molded geometry itself, resolving the contradiction between assembly ease and mounting precision.
2Ease of manufacture
If coil contacts are connected via separate coil wires, then electrical connection is established, but magnetic field consistency deteriorates
Solution Approach 1:
The patent merges the coil contacts with the coil holder structure, integrating electrical connection features directly into the molded component. This eliminates separate coil wires and their associated connection points, thereby maintaining magnetic field consistency while achieving electrical connection.
Solution Approach 2:
The injection-molded coil holder acts as an intermediary structure that provides both mechanical support and electrical connection pathways. By incorporating conductive elements or contact features directly into the mold, it mediates between the power supply and coils without introducing disruptive wire connections, thus maintaining field consistency.
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 solution enables precise and efficient assembly of the magnet system, reducing magnetic resistance and maintaining signal strength while simplifying the assembly process, thereby improving the accuracy and reliability of magnetic-inductive flow measurements.
Implementation Method 1
a magnetic system for generating a magnetic field perpendicular to the measuring tube
Implementation Method 2
a pair of measuring electrodes for detecting a flow-dependent electrical voltage induced in the medium by the magnetic field
Data Source
Figure 1
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AI summary
The invention relates to a method (100) for producing a coil holder (34) of a magnetic inductive flowmeter (1) by means of injection molding, the coil holder having two coil cores (33), which are potted in a plastic casting and each have a first longitudinal axis (L1), the method comprising the following steps: providing and positioning a casting mold having a casting volume and the two coil cores in a first method step (101), each coil core having two end faces and a lateral surface, the end faces of each coil core preferably orthogonally intersecting with the first longitudinal axis in question, the lateral surface having a center region (33.3) and two outer regions (33.4) delimiting the center region, the casting volume completely surrounding the center regions in respective coil regions, the outer regions and the end faces being spaced apart from the casting volume; filling the casting volume with a plastic in a second method step (102); allowing the plastic to harden in a third method step (103); removing the casting mold from the plastic casting in a fourth method step (104), the casting volume being contiguous.