Electromagnetic Flowmeter Electrode Plastic Welding Seal
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Solution Overview
Problem
Conventional magneto-inductive flowmeters face issues with electrode attachment, particularly in high-pressure applications and with plastic measuring tubes, leading to leakage and interference problems, and existing solutions are not effective in ensuring a liquid-tight and pressure-tight connection.
Innovation Solution
The use of a plastic fastening means connected to the measuring tube via plastic welding technology, creating a strong, inseparable bond that seals the electrode in place and prevents wobbling, ensuring a liquid-tight and pressure-tight connection, utilizing techniques like ultrasonic, resistance, or heat welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrode attachment methods (threaded caps, O-rings, springs) are used, then the electrode can be installed in the measuring tube, but the connection is not liquid-tight and pressure-tight, leading to leakage problems under high pressure
Solution Approach 1:
The electrode shaft is directly integrated into the measuring tube body without separate attachment components. The bore extends through the measuring tube wall and receives the electrode shaft directly, eliminating the need for threaded caps, O-rings, springs, or adhesive layers, thereby achieving a liquid-tight and pressure-tight connection while simplifying manufacturing
Solution Approach 2:
The intermediate attachment components (threaded caps, O-rings, adhesive layers) are completely removed from the electrode attachment system. Only the essential elements (bore and electrode shaft) remain, eliminating potential failure points and achieving reliable sealing under high pressure
2Ease of operation
If radial bores are created in the measuring tube for electrode insertion, then the electrode can be installed, but the bores become weak points leading to cracks and destruction under high pressure
Solution Approach 1:
The bore is designed with specific local characteristics: it extends only partially through the measuring tube wall (not completely through), and has a controlled cross-sectional area. This localized design maintains overall structural integrity while providing sufficient access for the electrode shaft, preventing the bore from becoming a weak point under high pressure
3Volume of moving object
If small nominal widths of measuring tubes are used, then the flow measurement is more compact, but it becomes difficult to attach electrodes and close the bore
Solution Approach 1:
All intermediate attachment components are removed, leaving only the essential bore and electrode shaft integration. This minimalistic approach eliminates the need for complex attachment procedures that would be difficult to implement in small measuring tubes, making the process feasible even with limited space
Solution Approach 2:
The electrode shaft is directly integrated into the measuring tube bore without separate attachment steps. This merging of components eliminates the need for multiple operations (attaching caps, installing O-rings, applying adhesives) that would be difficult to perform in small measuring tubes with limited access space
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 provides a robust, interference-free measurement signal by ensuring the electrode is fixed without play, reducing noise and maintaining the flow profile, and is applicable to both metallic and plastic measuring tubes, enhancing the structural integrity and corrosion resistance.
Implementation Method 1
a magnet system for generating a magnetic field
Implementation Method 2
Charge carriers in the medium moving perpendicularly to a magnetic field induce a voltage in the electrodes
Implementation Method 3
the fastening means is connected to the measuring tube by a plastic welding technique
Data Source
Figure 1
Figure 2~4
AI summary
A magnetic-inductive flow meter comprising a measurement recorder, wherein the measurement recorder comprises a flow tube through which a measured material can flow, a magnet system for producing a magnetic field, and at least one electrode disposed in the flow tube for detecting an electrical voltage, wherein a fastening means is provided for fastening the electrode to the flow tube, wherein the fastening means is made of plastic, at least partially, and wherein the fastening means is connected to the flow tube using a plastic welding technique. Also provided is a method for manufacturing a magnetic-inductive flow meter, wherein the magnetic-inductive flow meter comprises a flow tube, wherein the flow tube has at least one hole, wherein an electrode is inserted into the hole, and wherein the electrode is fastened to the flow tube using a plastic welding technique.