Modular Flow Resistance Element for Mass Flow Meters

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Solution Overview

Problem

Existing mass flow measurement and control devices require a range of complex and expensive flow resistance elements with different opening diameters to accommodate varying flow rates, which is costly and difficult to manufacture with precise tolerances, and can lead to undesirable turbulence due to sudden changes in cross-sectional area.

Innovation Solution

A modular flow resistance element composed of multiple parallel channels with thin walls, produced by photopolymerization, interacting with screens of varying diameters, allowing continuous adjustment of flow range using a single element, and featuring a trapezoidal channel cross-section for reduced turbulence and easy assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple flow resistance elements with different opening diameters are used to accommodate varying flow rates, then the device can handle a wide range of flow rates, but the device complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improveflow rate rangeVSAvoidnumber of flow resistance elements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single flow resistance element is designed with multiple adjustable screens of different opening diameters that can be interchanged within the same element. This allows one flow resistance element to perform multiple functions by accommodating different screens, thereby handling a wide range of flow rates without requiring multiple separate elements. The universal design reduces device complexity while maintaining adaptability across various flow rate requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple flow resistance elements with different opening diameters are used to accommodate varying flow rates, then the device can handle a wide range of flow rates, but the manufacturing cost increases

Engineering Contradiction:

Improveflow rate rangeVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By designing a universal flow resistance element that can accommodate multiple screens with different opening diameters, the manufacturing cost is reduced compared to producing multiple separate flow resistance elements. The single element structure with interchangeable screens allows cost-effective manufacturing while maintaining the capability to handle various flow rates through screen selection rather than element replacement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If conventional manufacturing methods are used for flow resistance elements, then the structure is simple to manufacture, but maintaining small tolerances and achieving low wall thicknesses is difficult

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwall thickness tolerance

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Conventional mechanical manufacturing methods are replaced with photopolymerization, an additive manufacturing process that builds structures layer by layer. This substitution enables precise control of wall thicknesses in the range of 0.05 mm to 0.5 mm and maintains very low tolerances, which are difficult to achieve with traditional mechanical machining or drilling methods. The photopolymerization process allows for complex channel geometries and thin walls to be manufactured with high precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If sudden narrowing or widening of cross section occurs at channel openings, then the manufacturing is simpler, but undesirable turbulence occurs

Engineering Contradiction:

Improvechannel geometry simplicityVSAvoidturbulence

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The channel cross-sectional geometry is optimized by using trapezoidal channels instead of simple cylindrical bores. This parameter change in channel shape allows for gradual transitions at the openings, reducing sudden narrowing or widening effects that cause turbulence. The trapezoidal geometry provides smoother flow entry and exit, minimizing harmful turbulence while maintaining manufacturing feasibility through the photopolymerization process.

Inventive Principle:

Principle #35Parameter changes

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 reduces production costs, maintains low tolerances, and minimizes turbulence, enabling efficient and cost-effective adjustment of flow rates across a wide range in mass flow meters and control devices.

Implementation Method 1

These generate a slight drop in pressure, which causes a flow through a bypass duct

Methodology Applied

Scientific EffectPressure drop: Pressure Drop

Implementation Method 2

The flow resistance element according to the invention is preferably produced by photopolymerization from a plastic by layered growth over a corresponding mask

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentEP2275785B1Modular unit

Publication Date: 2016.10.19 BUERKERT WERKE GMBH & CO KG

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AI summary

A modular unit consists of a flow resistance element and an adjacent orifice, preferably for use in the main flow channel of a thermal mass flow meter or control device. The flow resistance element can be combined with various orifices that differ in their opening diameter.