Magnetic Flowmeter Assembly Framework for Reduced Variability
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Solution Overview
Problem
The assembly of magnetic flowmeters is labor intensive, complicated, and prone to variability and errors due to the lack of integrated or multifunctional parts, leading to increased complexity and cost.
Innovation Solution
A magnetic flowmeter design featuring a framework that surrounds and secures the pipe, with hinged segments to conform to the pipe's shape, and snap features to hold components in precise positions, reducing variability and simplifying assembly by fixing the positional relationships of coils, electrodes, and wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate components and multiple fasteners are used to assemble saddle coils to pipes, then the flowmeter can be assembled, but the assembly process becomes labor intensive and complicated
Solution Approach 1:
The patent integrates the saddle coil, mounting bracket, and fastening mechanisms into a single integrated assembly unit. This merging of previously separate components (coil windings, tape wrapping, mechanical fasteners, and mounting structures) into one pre-assembled unit eliminates the need for multiple separate assembly steps and reduces labor intensity while maintaining secure attachment to the pipe.
Solution Approach 2:
The saddle coil assembly is pre-assembled and pre-positioned as a complete unit before installation on the pipe. The coil windings are already wrapped with protective tape, secured with fasteners, and mounted on the bracket in advance, so that during final installation, the entire assembly is simply attached to the pipe in one action rather than constructing it on-site.
2Manufacturing precision
If traditional saddle coil assembly methods are used, then the flowmeter can be manufactured, but the process is prone to variability and errors
Solution Approach 1:
The patent divides the flowmeter assembly into distinct modular segments: the integrated saddle coil assembly unit and the pipe mounting structure. This segmentation allows each module to be manufactured and quality-checked independently under controlled conditions, ensuring consistent positioning and reducing assembly variability when the modules are combined.
Solution Approach 2:
The patent specifies precise geometric parameters and tolerances for the integrated saddle coil assembly, including the positioning of coil windings, the dimensions of mounting brackets, and the placement of fasteners. By controlling these dimensional parameters during manufacturing, the assembly process achieves higher consistency and reduced variability across different production batches.
3Ease of manufacture
If multiple separate parts are used in the magnetic flowmeter, then the components can be assembled, but the parts count increases and cost increases
Solution Approach 1:
The patent combines multiple previously separate components into integrated assemblies. Specifically, the saddle coil windings, protective tape wrapping, mechanical fasteners, and mounting brackets are merged into a single integrated saddle coil assembly unit, reducing the total parts count from multiple discrete components to fewer modular units that are easier to manufacture and assemble.
Solution Approach 2:
The integrated saddle coil assembly serves multiple functions simultaneously: it provides the magnetic field generation (coil function), structural support and positioning (mounting bracket function), electrical insulation and protection (tape wrapping function), and mechanical attachment to the pipe (fastening function). This multi-functionality eliminates the need for separate components for each function, reducing overall parts count.
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 design improves manufacturability, reduces parts count, enhances performance consistency, and protects wiring from shorting, resulting in improved accuracy and reduced assembly complexity.
Implementation Method 1
Magnetic flowmeters (or mag meters) measure flow by Faraday induction, an electromagnetic effect. The meter energizes a coil (or coils) to generate a magnetic field across a pipe section, and the magnetic field induces an electromotive force (EMF) across the process flow.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A magnetic flowmeter 10 includes a pipe section 12, coils 16A and 16B for generating a magnetic field across the pipe section 12, and electrodes 18A and 18B for sensing EMF induced by process fluid flow through the magnetic field. An assembly framework 24A, 24B is mounted on the pipe. The coils 16A, 16B, electrodes 18A, 18B, and associated wiring 20A, 20B, 22A, 22B, 44 of the flowmeter 10 are located and secured in place by the framework 24A, 24B.