Multi-Apex Flow Obstruction Structure for Precise Flow Measurement
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Solution Overview
Problem
Existing fluid obstruction devices in process fluid flow measurement devices face challenges in manufacturing accuracy and efficiency, particularly with external wedges due to tolerances and weld deformation, and internal wedges due to material waste and specialized EDM processes.
Innovation Solution
A fluid flow obstruction device with a self-supporting structure comprising multiple walls and ribs, allowing for customizable h/D ratios through late-stage modifications, manufactured using additive manufacturing techniques like laser powder bed fusion, which enhances manufacturing tolerances and reduces material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external wedge elements are used, then manufacturing simplicity is improved, but manufacturing precision deteriorates due to tolerances and weld deformation
Solution Approach 1:
The patent combines multiple wedge elements into a single integrated structure with multiple walls forming multiple apices. This merging eliminates the need for separate welding operations for each wedge element, thereby maintaining manufacturing simplicity while improving measurement precision by eliminating weld deformation errors.
Solution Approach 2:
The wedge structure is segmented into multiple walls (first wall, second wall, third wall, fourth wall) forming multiple apices. Each wall can be manufactured with standard tolerances, and the segmented design allows for easier assembly without requiring high-precision welding, thus resolving the contradiction between manufacturing simplicity and precision.
2Manufacturing precision
If internal wedge elements are used, then manufacturing precision is improved, but material waste increases and device complexity increases due to specialized EDM processes
Solution Approach 1:
Multiple wedge elements are merged into a single integrated structure that can be manufactured as one piece using additive manufacturing. This eliminates the need for specialized EDM processes and reduces material waste by optimizing the use of bar stock, while maintaining the precision benefits of internal wedge elements.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional subtractive methods (EDM) to additive manufacturing (laser powder bed fusion). This parameter change enables complex multi-wall wedge structures to be manufactured with less material waste and without requiring specialized EDM equipment, while maintaining high manufacturing precision.
3Manufacturing precision
If internal wedge elements are used, then manufacturing precision is improved, but device complexity increases due to specialized EDM process capabilities
Solution Approach 1:
The manufacturing process parameter is changed from specialized subtractive EDM to additive manufacturing using laser powder bed fusion. This parameter change simplifies the manufacturing process by eliminating the need for specialized EDM equipment and complex fixturing, while maintaining the ability to produce high-precision multi-wall wedge structures.
Solution Approach 2:
The patent replaces the mechanical EDM process with an additive manufacturing process. This substitution eliminates the need for complex mechanical fixturing and specialized EDM equipment, reducing device complexity while maintaining manufacturing precision through digital modeling and controlled material deposition.
4Adaptability or versatility
If customizable h/D ratios are implemented, then adaptability is improved, but device complexity increases
Solution Approach 1:
The wedge structure is segmented into multiple walls that can be independently configured to create different apex positions and h/D ratios. This segmentation allows customization of the flow measurement characteristics without requiring completely different device designs, maintaining adaptability while managing structural complexity through modular wall configurations.
Solution Approach 2:
The multi-wall wedge structure serves multiple functions: it can be configured for different h/D ratios, maintains structural integrity, and provides accurate flow measurement. This universal design allows a single device structure to accommodate multiple measurement requirements, improving adaptability without proportionally increasing device complexity.
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 improved manufacturing accuracy and efficiency by enabling customizable h/D ratios with reduced material waste and specialized tooling requirements, resulting in a cost-effective and practical fluid flow obstruction device.
Implementation Method 1
manufactured using additive manufacturing techniques like laser powder bed fusion
Implementation Method 2
laser powder bed fusion
Data Source
Figure 1~2A
Figure 2B
Figure 2C
AI summary
A fluid flow obstruction device (1) for a process fluid flow measurement device (9) includes a first wall (11) having a first side. A second wall (15) having a proximate end is arranged at a proximate end of the first side of the first wall (11). The arrangement forms a first apex (60) between the first wall (11) and the second wall (15). At least one additional wall (18) is arranged parallel to the second wall (15) at a distance from the proximate end of the first side of the first wall (11). The arrangement of the at least one additional wall (18) and the first wall forms a corresponding additional apex (61).