Modular Water Meter Casing Segmentation for Cost Reduction
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Solution Overview
Problem
The high cost and complexity of producing metallic water meter casings using one-piece casting methods, which can result in thick walls and the use of harmful substances, necessitate a more efficient and cost-effective manufacturing process.
Innovation Solution
A modular water meter casing design comprising separate components such as a middle casing, water inlet port, and water outlet port, connected via welding and threads, utilizing the high pressure liquid bulging method for processing, which includes a fluid director, external adjusting fluid director, movement guider, and support ring, allowing for simpler processing and reduced material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If one-piece casting method is used to manufacture metallic water meter casing, then the structural integrity is improved, but the production cost increases and the wall thickness becomes excessive
Solution Approach 1:
The water meter casing is divided into multiple separate components including the body, inlet port, outlet port, and baseplate. These components are manufactured separately using stamping and forming processes, then assembled together through welding and threading. This segmentation allows each part to be optimized independently, reducing material waste and production costs while maintaining overall structural integrity through proper joining methods.
2Strength
If one-piece casting method is used, then the structural integrity is improved, but the wall thickness becomes very thick
Solution Approach 1:
By dividing the casing into separate components, each part can be formed with optimal wall thickness for its specific function. The stamping and forming processes allow for thinner, more efficient wall sections compared to cast parts, reducing overall material volume while maintaining strength through design optimization and proper joining.
Solution Approach 2:
Different sections of the casing have different structural requirements. The segmented design allows each component to have locally optimized wall thickness and geometry suited to its specific functional demands, rather than requiring uniform thick walls throughout the entire casing as would be necessary with one-piece casting.
3Ease of manufacture
If one-piece casting method is used, then the manufacturing process is simplified, but harmful substances are generated and production cost increases
Solution Approach 1:
The manufacturing process is segmented into separate stamping, forming, welding, and threading operations. This eliminates the need for casting processes that generate harmful emissions and require toxic molding materials. Each component is formed through metal forming processes that are environmentally friendly, and the assembly process uses standard welding and machining operations without harmful byproducts.
4Ease of manufacture
If separate components are used, then the production cost is reduced and material thickness is optimized, but the assembly complexity increases
Solution Approach 1:
While the casing is segmented into multiple components, the assembly process is simplified through standardized joining methods. Threads are formed on specific components for easy screw-together assembly, and welding is used for permanent joints where appropriate. This modular approach with standardized connections actually reduces assembly complexity compared to one-piece casting, as components can be pre-manufactured and assembled in a systematic manner.
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 approach reduces production costs, increases labor productivity, and ensures the use of hygienic materials, minimizing environmental impact and secondary pollution, while maintaining the structural integrity and accuracy of the water meter.
Implementation Method 1
the hydraulic method is used for processing and molding the water inlet port and the water outlet port of said water meter casing
Implementation Method 2
the water bulging method is used for processing and molding the middle casing of said water meter casing
Implementation Method 3
The water inlet port and water outlet port are respectively welded on the water inlet and the water outlet
Data Source
AI summary
A water meter casing and manufacturing process thereof are provided. The water meter casing comprises a middle casing (1), a water inlet port (2) and a water outlet port (3), which are separate parts, wherein a water inlet (4) and a water outlet (5) where the water inlet and outlet ports (2, 3) are arranged are respectively provided at the two sides of the middle casing (1), and a support ring (6) is also provided in the inner cavity of the middle casing (1). The manufacturing process of the water meter casing relates to a method of forming the water meter casing by high pressure hydraulic bulging. The manufacturing process is simple and easy to carry out, and it presents the advantage of low cost.