Modular Flowtube Assembly for Magnetic Flowmeter
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Solution Overview
Problem
Magnetic flowmeters used in abrasive and corrosive applications face frequent wear and tear, leading to costly and time-consuming replacements of the entire flowtube assembly, as traditional designs require disassembly and are prone to leaks and permeation issues, necessitating frequent replacement every 6-18 months.
Innovation Solution
A modular flowtube assembly design featuring a separate removable liner/electrode module and a housing module, where the liner/electrode module can be replaced without disassembling the housing, with electrical connections routed through interconnect tabs to prevent leaks and allow for easy maintenance, reducing the need for frequent replacement of non-wearing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire flowtube assembly is replaced when the liner and electrodes wear out, then the flowmeter can be restored to full functionality, but the cost and time required for maintenance increases significantly
Solution Approach 1:
The flowtube assembly is divided into separate modular components: the housing module containing the coil and electronics, and the removable liner/electrode module. This segmentation allows the liner and electrodes to be replaced independently without replacing the entire assembly, reducing maintenance time and cost while restoring flowmeter functionality.
Solution Approach 2:
The liner and electrodes are extracted as a separate removable module from the housing. This extraction allows the wearing components to be replaced independently, eliminating the need to replace or disassemble the housing and coil assembly, thereby reducing maintenance time and cost.
2Reliability
If the entire flowtube assembly is replaced when the liner and electrodes wear out, then the flowmeter can be restored to full functionality, but the cost of maintenance increases
Solution Approach 1:
The flowtube assembly is segmented into housing and liner/electrode modules, allowing replacement of only the worn components (liner and electrodes) rather than the entire assembly. This reduces material cost by retaining reusable components like the housing and coil.
Solution Approach 2:
The liner and electrodes are discarded when worn, but the housing module containing the expensive coil and electronics is recovered and reused. This selective discarding and recovery significantly reduces maintenance costs compared to replacing the entire assembly.
3Ease of repair
If the liner/electrode module is made removable without disassembling the housing, then maintenance becomes easier, but the device structure becomes more complex
Solution Approach 1:
The assembly is segmented into modular components with standardized interfaces. The removable liner/electrode module connects to the housing through simple mounting flanges and sealing mechanisms, providing ease of maintenance while adding only minimal structural complexity compared to a monolithic design.
4Adaptability or versatility
If traditional flowtube assemblies are used in abrasive applications, then the flowmeter can measure corrosive fluids, but the liner and electrodes wear out frequently requiring replacement every 6-18 months
Solution Approach 1:
The liner and electrodes are segmented into a separate removable module that can be easily replaced when worn. This allows frequent replacement of the consumable liner/electrode module while retaining the durable housing, maintaining the ability to measure corrosive fluids while managing the limited lifespan of the liner and electrodes.
Solution Approach 2:
The liner and electrodes are treated as disposable or short-living components that are replaced frequently in abrasive applications. The removable module design allows these consumable parts to be replaced economically without wasting the durable housing and coil assembly.
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 reduces maintenance costs and downtime by allowing the replacement of only the worn-out liner/electrode module, extending the life of the flowmeter and minimizing labor and replacement costs, while maintaining accurate flow measurements.
Implementation Method 1
Magnetic flowmeters (or mag meters) measure flow by Faraday induction, an electromagnetic effect. The magnetic flowmeter energizes a coil which generates a magnetic field across a section of a flowtube assembly.
Implementation Method 2
The magnetic field induces an electromotive force (EMF) across the flow of conductive process fluid. The resulting potential developed across the conductive fluid is measured using a pair of electrodes
Data Source
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AI summary
A flowtube assembly (10) for a magnetic flowmeter is provided. The flowtube assembly (10) includes a tube (12) extending from a first mounting flange (14) to a second mounting flange (16). Each of the first and second mounting flanges (14,16) has a pipe flange facing surface (15, 17) for mounting to a respective pipe flange. A coil chamber (42) is disposed outside the tube (12), between the first and second mounting flanges (14,16). The coil chamber (42) has at least one coil (40) located inside that is configured to generate a magnetic field within the tube (12). A liner/electrode module (22) is positioned within the tube (12) and has a non- conductive liner, at least one electrode (50, 51) and at least one electrode conductor (76,78). The non-conductive liner extends from the first mounting flange (14) to the second mounting flange (16). The at least one electrode (50, 51) is positioned in the non-conductive liner to interact with a conductive process fluid. The electrode conductor (76,78) extends from the at least one electrode (50, 51) to an interconnect tab (24) disposed adjacent the pipe facing flange surface of one of the first and second mounting flanges (14,16). The liner/electrode module (22) is positionable within the tube (12).