Monolithic Metal Connection Element for Thermal Flow Sensors
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Solution Overview
Problem
Conventional thermal flow measuring devices face measurement errors due to heat transfer changes at weld seams, and components manufactured by non-standard methods, such as MIM or SLM, may not withstand the required pressure for flow measurement applications.
Innovation Solution
A flow measuring device with a monolithic metal connection element that connects measurement signal-generating sensor elements to a pipe or tube, using generative manufacturing methods to ensure seamless heat transfer and pressure resistance, featuring a pressure-bearing component with a potting compound to prevent medium leakage at high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to connect pin sleeves with the cylindrical hollow body, then the connection is strong and structurally sound, but heat transfer changes with temperature change at the weld seams, leading to measurement errors
Solution Approach 1:
The patent merges the pin sleeves and cylindrical hollow body into a single monolithic sensor housing manufactured by generative manufacturing methods. This eliminates the weld seam interface that causes heat transfer changes, while maintaining structural strength through the integrated design. The measurement signal-generating sensor elements are connected to this monolithic housing, ensuring consistent heat transfer throughout the connection component.
Solution Approach 2:
The patent employs a connection component made from granular material (metal powder or metal grains) processed through generative manufacturing methods like SLM or MIM. This creates a composite structure that combines the benefits of metal material strength with a seamless, weld-free design, resolving the contradiction between connection strength and measurement precision.
2Measurement precision
If monolithic sensor housing is manufactured by generative manufacturing methods (SLM or MIM), then heat transfer remains consistent and measurement accuracy improves, but the component may not withstand the required pressure of up to 40 bar
Solution Approach 1:
The patent applies parameter changes by carefully controlling the manufacturing parameters of the generative manufacturing process, including material composition, layer thickness, and processing parameters. These parameter optimizations ensure that the monolithic connection component achieves both the required pressure resistance (withstanding up to 40 bar) and consistent heat transfer properties for accurate flow measurement.
3Strength
If standard manufacturing methods are used, then components can withstand pressure requirements, but complicated forms and functional properties cannot be implemented
Solution Approach 1:
The monolithic connection component manufactured by generative manufacturing methods serves multiple functions simultaneously: it provides structural support to withstand pressure, ensures consistent heat transfer for measurement accuracy, and integrates the measurement signal-generating sensor elements directly into the housing. This multi-functional design eliminates the need for separate components while meeting all performance requirements.
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 solution provides accurate flow measurements by maintaining consistent heat transfer and withstanding pressures up to 40 bar, preventing medium leakage and ensuring the stability of the connection under high-pressure conditions.
Implementation Method 1
heat transfer changes with temperature change
Data Source
AI summary
A flow measuring device comprising a measurement signal-generating sensor element and a metal connection element, especially one manufactured in a generative manufacturing method, for connecting the measurement signal-generating sensor element with an opening or sensor nozzle of a tube, where the connection element is connected with a pressure-bearing component comprising a sleeve and a wall, which extends over the entire cross section in parallel projection in the direction of a longitudinal axis of the sleeve, wherein the pressure bearing component has at least one electrical cable guide and a potting compound, wherein the potting compound fills the sleeve partially or completely, and wherein the pressure bearing component is arranged in the opening or in the sensor nozzle of the tube radially behind the connection element with reference to the longitudinal axis of the tube.