Inline Ultrasonic Flow Meter Assembly for Accurate Low-Flow Measurement
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Solution Overview
Problem
Traditional clamp-on ultrasonic flow meters require multiple installation details that are difficult to obtain and detect, leading to inaccurate measurements and increased maintenance, while in-line transducers suffer from performance challenges.
Innovation Solution
An inline flow meter assembly with axially-aligned transducers that eliminate the need for signal reflection off pipe walls, featuring a housing with a measurement channel and transducers sealed from fluid flow, allowing precise and accurate measurement of low flow rates without requiring realignment for different fluid types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If clamp-on transducers are used with one-size-fits-all design, then manufacturing is simplified and inventory is minimized, but installation accuracy deteriorates due to multiple installation details required
Solution Approach 1:
The patent applies local quality by providing transducer assemblies with specific adaptations for different pipe configurations. Instead of a universal clamp-on design, the invention uses locally optimized transducer placements and orientations that account for specific pipe materials, wall thicknesses, and diameters, thereby improving measurement accuracy while maintaining manufacturing simplicity through modular design approaches.
Solution Approach 2:
The patent employs parameter changes by adjusting transducer frequency, power, and timing parameters based on detected pipe characteristics. The system measures pipe wall thickness and material properties, then dynamically modifies ultrasonic transmission parameters to optimize signal penetration and measurement accuracy for each specific installation scenario.
2Measurement precision
If clamp-on transducers require multiple installation details, then measurement accuracy can be improved, but installation time and complexity increase
Solution Approach 1:
The patent applies preliminary action by performing pipe characteristic measurements (wall thickness, material type, diameter) during the installation process itself, before final transducer positioning. The system includes integrated sensors that automatically detect and store these parameters, eliminating the need for installers to manually gather multiple installation details and reducing installation time while maintaining accuracy.
Solution Approach 2:
The patent implements self-service by enabling the transducer assembly to automatically detect and adapt to pipe characteristics without external input. The system self-calibrates by measuring pipe wall properties and automatically adjusting measurement parameters, eliminating the need for installers to manually input multiple installation details and reducing installation complexity.
3Measurement precision
If clamp-on transducers use grease to fill air gaps, then measurement accuracy is improved, but maintenance requirements increase
Solution Approach 1:
The patent applies the taking out principle by eliminating the grease requirement entirely. The design uses direct contact mounting surfaces with integrated sealing features that create acoustic coupling without requiring external grease or gel materials. This extraction of the grease component removes the maintenance burden of periodic grease replacement while maintaining signal transmission accuracy through precision-machined contact surfaces.
4Productivity
If clamp-on transducers are installed externally, then system shutdown is avoided, but transducers are susceptible to external forces and movement
Solution Approach 1:
The patent applies the nested doll principle by integrating the transducer assembly within a protective housing that is itself installed within the pipe structure. The transducer is nested within a sealed chamber that is attached to the pipe exterior, providing mechanical protection against external forces while maintaining the non-intrusive installation approach that avoids system shutdown.
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
The inline flow meter assembly provides improved measurement accuracy, reduced installation time, and lower inventory costs by eliminating the need for signal reflection and simplifying installation, enabling precise measurement of low flow rates.
Implementation Method 1
a transducer positioned within the elongate portion and sealed from fluid flow past the outer cup portion, the transducer having a width perpendicular to the housing axis and greater than the width of the measurement channel, the transducer configured to generate an ultrasonic signal and to direct the ultrasonic signal through the measurement channel
Data Source
AI summary
A flow rate assembly can include a housing having a measurement channel extending along the housing axis and through a portion of the housing between the first and second ends of the housing, an outer cup portion positioned at least partly within the housing, and a transducer positioned within the outer cup portion and sealed from fluid flow past the outer cup portion, the transducer having a width perpendicular to the housing axis and greater than the width of the measurement channel, the transducer configured to generate an ultrasonic signal and to direct the ultrasonic signal through the measurement channel.