Symmetric Sensor Bracket and Tube Ring for Reliable Conduit Brazing
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Solution Overview
Problem
Existing sensor brackets for vibratory conduits are complex and expensive to manufacture, prone to failure due to high stresses and dynamic forces, and often fail to reliably affix to the conduit, leading to issues with brazing joints.
Innovation Solution
A sensor assembly comprising a sensor bracket and tube ring with complementary portions that are symmetrically designed to interface with each other and the conduit, reducing stress and allowing for inexpensive, tightly controlled manufacturing, thereby enhancing the reliability of the brazing joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex bracket assemblies with multiple pieces are used to affix sensors to the vibratory conduit, then the sensors can be mounted, but the manufacturing cost and assembly complexity increase significantly
Solution Approach 1:
The bracket is divided into two functional segments: a tube ring that interfaces with the vibratory conduit and a bracket body that mounts the sensor. This segmentation allows each part to be optimized independently for its specific function while simplifying the overall assembly process.
Solution Approach 2:
The tube ring is positioned within or around the vibratory conduit, and the bracket body is attached to the tube ring, creating a nested structure where smaller components are integrated within or around larger ones, reducing overall complexity.
2Ease of manufacture
If brackets contact the conduit at only a point rather than along a line or multiple points, then the bracket design is simpler, but the brazed joint fails due to high stresses and dynamic forces
Solution Approach 1:
The contact interface is extended from a zero-dimensional point contact to a one-dimensional line contact or two-dimensional surface contact along the vibratory conduit, distributing stresses across multiple points and preventing brazed joint failure.
3Manufacturing precision
If alignment jigs are used to affix brackets to the vibratory conduit, then proper alignment is achieved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The tube ring and bracket body incorporate self-aligning features such as complementary geometric shapes, keyed interfaces, or tolerance-built-in designs that automatically ensure proper alignment during assembly without requiring external alignment jigs or fixtures.
4Ease of manufacture
If simple bracket designs are used that do not contact the conduit at multiple points, then manufacturing is easier, but the brackets are not reliably affixed to the vibratory conduit
Solution Approach 1:
The bracket system is segmented into a tube ring for conduit interface and a bracket body for sensor mounting, with each segment optimized for its specific function while maintaining ease of manufacture.
Solution Approach 2:
The contact interface is extended from point contact to line or surface contact along the conduit, distributing stresses and ensuring reliable affixation while keeping the overall design simple and easy to manufacture.
Data Source
AI summary
A sensor assembly (100, 300) for a vibratory conduit (130a, 330) is provided. The sensor assembly (100, 300) includes a sensor bracket (110, 310) having an outer surface (112, 312) substantially symmetric about an axis (S) and including a complementary portion (112c, 312c). The sensor assembly (100, 300) also includes a tube ring (120, 220, 320) having an outer surface (122, 222, 322) including a complementary portion (122c, 222c, 322c) affixed to the complementary portion (112c, 312c) of the sensor bracket (110, 310). The axis (S) of the sensor bracket (110, 310) is external of the vibratory conduit (130a, 330) when the tube ring (120, 220, 320) is affixed to the vibratory conduit (130a, 330).