Polymer Reflector-Holder Assembly for Low-Turbulence Ultrasonic Meters
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Solution Overview
Problem
Existing ultrasonic meters face challenges in the stable and repeatable assembly of reflectors, manual assembly complexity, fluid turbulence, pressure differences, and high production costs, while maintaining measurement precision and reducing turbulence.
Innovation Solution
A reflector-holder device with polymeric pieces and integrated reflector supports, overmolded during molding, ensures stable reflector positioning, reduces turbulence, and minimizes pressure loss, allowing efficient and cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reflectors are positioned on support bodies with radial arms in known solutions, then reflector assembly is achieved, but unwanted turbulence is created in the fluid flow
Solution Approach 1:
The invention extracts and removes the radial arms from the support body design. Instead of having arms extending into the fluid flow path, the support body is designed with a streamlined shape that follows the duct contour, eliminating the source of turbulence while maintaining reflector positioning capability.
Solution Approach 2:
The support body shape is changed from a traditional radial arm structure to an aerodynamic/streamlined profile. This parameter change in geometry reduces flow separation and turbulence generation, allowing the support body to blend smoothly with the fluid flow while still providing stable reflector mounting.
2Ease of manufacture
If manual fixing of reflectors is used in known solutions, then assembly is performed, but high complexity and labor are required
Solution Approach 1:
The reflector and support body are merged into a single integrated component. The reflector is directly formed as part of the support body structure, eliminating the need for separate fixing operations, fasteners, or assembly steps. This integration simplifies manufacturing while ensuring precise reflector positioning.
Solution Approach 2:
The support body is designed to be self-positioning and self-supporting within the duct. The streamlined shape provides inherent stability and alignment in the fluid flow, eliminating the need for complex external fixing mechanisms or manual adjustment procedures.
3Manufacturing precision
If radial arms are used to extend into the duct, then reflector positioning is achieved, but pressure loss increases due to flow disruption
Solution Approach 1:
The support body is designed with curved, aerodynamic surfaces that follow the natural flow lines of the fluid. This curved geometry eliminates sharp edges and protrusions that would cause flow separation and pressure loss, while still providing the necessary structural support for precise reflector positioning.
Solution Approach 2:
Instead of extending radial arms perpendicular to the duct surface, the support body integrates along the duct's longitudinal dimension with a streamlined profile. This dimensional reconfiguration allows the support structure to be embedded within the flow path rather than protruding into it, minimizing pressure loss.
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 a highly stable and repeatable assembly of reflectors, reduces turbulence, minimizes pressure loss, and ensures precise and efficient fluid measurement with reduced material usage and production costs.
Implementation Method 1
the ultrasonic signals emitted by a transducer are guided towards the receiving transducer by one or more reflectors, thus defining a reflection path with a shape such as a 'U', 'V' or 'W'
Data Source
Figure 1~2
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Figure 5~6C
AI summary
Reflector-holder device (1) for an ultrasonic meter (3) of a fluid, preferably a liquid, said device (1) being suitable to be inserted into a duct (2) for the passage of the fluid of said meter (3), said device (1) being characterised by comprising a first piece (20) and a second piece (30) which: - are made by moulding in polymeric or polymer-based material, - once printed they are configured to be joined together to define, following their union, a tubular element (40) which is intended to be passed through by the fluid to be measured and wherein said tubular element (40) comprises: - a first mouth (44') for the entry or exit of the fluid to be measured into/from said tubular element (40), - a second mouth (44") for the exit or entry of the fluid from/into said tubular element (40), said device (1) being also characterised in that: - the first piece (20) comprises a first support (45) of a first reflector (55) for reflecting ultrasonic signals and a second support (46) of a second reflector (56) for reflecting ultrasonic signals, - said first reflector (55) is fixed to the first support (45) and said second reflector (56) is fixed to the second support (46) during the moulding of said first piece (20) comprising said two supports (45, 46), - said two supports (45, 46) with their respective reflectors (55, 56) face each other and are both inclined towards the inside of the tubular element (40), - said two supports (45, 46) with their respective reflectors (55, 56) are entirely positioned inside the tubular element (40) between said first mouth (44') and said second mouth (44").