Multi-Apex Flow Obstruction Structure for Accurate Wedge Metering
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Solution Overview
Problem
Existing fluid flow measurement devices, particularly wedge-style flow meters, face challenges in accuracy due to manufacturing tolerances and material waste, with external wedges offering reduced accuracy and internal wedges requiring specialized equipment and causing material handling risks.
Innovation Solution
A fluid flow obstruction device with a design that includes a first wall and a second wall forming a first apex, with additional walls arranged parallel to the second wall to form corresponding apices, allowing for adjustable h/D ratios and reduced material usage through additive manufacturing, enabling late-stage customization and improved manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external wedge elements are used, then manufacturing complexity is reduced, but measurement precision deteriorates due to tolerances and weld deformation
Solution Approach 1:
The wedge element is divided into multiple segments or sections that can be manufactured separately with standard tolerances and then assembled together. This segmentation allows each part to be manufactured using conventional welding and machining processes while maintaining overall geometric accuracy through precise assembly procedures, thereby resolving the contradiction between ease of manufacture and measurement precision.
2Measurement precision
If internal wedge elements are manufactured with high precision, then measurement precision improves, but device complexity increases due to specialized EDM equipment requirements
Solution Approach 1:
The complex geometric features that traditionally required specialized EDM equipment are extracted or removed from the wedge element design. Instead of machining intricate internal geometries, the invention uses simpler wedge shapes that can be manufactured with standard equipment, while maintaining measurement precision through alternative means such as improved material selection, surface finishing processes, or calibration procedures.
3Manufacturing precision
If internal wedge elements are manufactured from large bar stock, then manufacturing precision improves, but loss of substance increases due to material waste
Solution Approach 1:
Instead of manufacturing the entire wedge element from a single large bar stock, the invention applies local quality by using different materials or material treatments for different sections of the wedge. High-precision, wear-resistant materials are applied only to the critical measurement surfaces, while other portions use less expensive, easier-to-manufacture materials. This approach maintains manufacturing precision where needed while significantly reducing overall material waste.
4Adaptability or versatility
If multiple h/D ratios are provided for different applications, then adaptability improves, but device complexity increases due to multiple components
Solution Approach 1:
The wedge element incorporates adjustable or variable geometry features that allow the h/D ratio to be dynamically changed without replacing the entire device. This may include movable sections, adjustable positioning mechanisms, or reconfigurable geometries that enable a single wedge element to function across multiple h/D ratios, thereby improving adaptability while reducing 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
This design enhances the accuracy and reduces material waste in fluid flow measurement devices by allowing for multiple h/D ratios in a single device, minimizing material usage and requiring less specialized equipment, thus improving manufacturing efficiency and accuracy.
Implementation Method 1
The fluid obstruction device causes a differential pressure to be developed between the upstream and downstream sides of the obstruction, which is related to the flow rate of the fluid
Data Source
AI summary
A fluid flow obstruction device for a process fluid flow measurement device includes a first wall having a first side. A second wall having a proximate end is arranged at a proximate end of the first side of the first wall. The arrangement forms a first apex between the first wall and the second wall. At least one additional wall is arranged parallel to the second wall at a distance from the proximate end of the first side of the first wall. The arrangement of the at least one additional wall and the first wall forms a corresponding additional apex.