Modular Electromagnetic Flow Sensor Insertion Design
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Solution Overview
Problem
Existing electromagnetic flow meters face challenges in low-cost high-volume manufacturing due to size-specific components, are prone to damage from misalignment stress, and have reduced sensitivity and increased power consumption due to coil placement and material limitations.
Innovation Solution
A modular electromagnetic flow sensor design with a magnetic circuit and electrodes configured for insertion into a flow tube through a single aperture, allowing for various sizes and materials, and a single register design that fits different flow tubes with flow conditioning inserts for turndown range and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electromagnetic coils are arranged around the outside of a plastic flow pipe, then the flow meter can be manufactured with simpler assembly, but the flow meter becomes prone to damage from misalignment stress and the coils are located further from the flow channel reducing sensitivity
Solution Approach 1:
The patent merges the electromagnetic coils with the flow channel by forming the coils as integral parts of the flow channel structure itself, rather than as separate external components. This integration eliminates the need for separate assembly of coils around the flow pipe, while simultaneously improving reliability by removing the plastic flow pipe that is prone to stress damage from misalignment.
Solution Approach 2:
The patent extracts the plastic flow pipe from the structural role and replaces it with a resilient metal flow channel that can withstand misalignment stress. The plastic is removed from load-bearing applications where it would crack under stress, while the metal structure provides the necessary mechanical strength and durability.
2Ease of manufacture
If electromagnetic coils are arranged around the outside of a plastic flow pipe, then assembly is simpler, but the coils are located further away from the flow channel resulting in a weaker magnetic field and reduced sensitivity
Solution Approach 1:
The electromagnetic coils are merged with the flow channel structure, forming an integrated assembly where the coils are positioned in optimal proximity to the flowing fluid. This integration eliminates the need for external coil mounting while maximizing the magnetic field strength within the flow channel, thereby improving measurement sensitivity.
3Manufacturing precision
If a specific set of component parts is manufactured for each size of flow meter, then each size can be optimized for its specific application, but manufacturing costs increase due to multiple assembly lines
Solution Approach 1:
The patent employs universal component designs that can be used across multiple flow meter sizes. The flow conditioning inserts, electromagnetic coils, and electrode assemblies are designed as standardized components that can be adapted to different pipe diameters, eliminating the need for completely separate component sets for each size and reducing manufacturing complexity.
Solution Approach 2:
The flow meter is segmented into modular components including a reusable body, interchangeable flow conditioning inserts, and standardized electromagnetic assemblies. This segmentation allows different size-specific features to be isolated to replaceable inserts while the core components remain universal, enabling cost-effective manufacturing across multiple sizes.
4Reliability
If electrical parts are encapsulated with a potting compound after assembly, then water ingress is prevented, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent replaces the chemical/thermal process of potting compound encapsulation with a mechanical sealing system using O-rings and gaskets. This substitution maintains water ingress prevention while dramatically simplifying the manufacturing process, eliminating the need for curing cycles and complex encapsulation equipment.
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
Enables cost-effective production of a range of flow meter sizes with improved sensitivity and reduced power consumption, while maintaining accuracy and durability by optimizing magnetic field generation and electrode placement.
Implementation Method 1
a part of a magnetic circuit supported by the body or frame for directing a magnetic field across the passage
Implementation Method 2
The first and second electrodes are arranged to sense a voltage in response to a conductive fluid (such as water) flowing through the passage
Data Source
AI summary
An electromagnetic flow sensor for an electromagnetic flow meter (201) is disclosed. The sensor comprises a body (204) or frame, a flow passage (252) through the body or frame, a part of a magnetic circuit (248, 295) supported by the body or frame for applying a magnetic field across the flow passage, and at least first and second electrodes (298) supported by the body or frame, the at least first and second electrodes arranged to sense a voltage in response to a conductive fluid flowing through the flow passage. At least a portion of the body supporting the magnetic circuit part and the at least first and second electrodes is configured to be insertable into a flow tube (206) through a single aperture in the flow tube.