Ultrasonic Flow Meter Transducer Assembly Transformer Relocation
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Solution Overview
Problem
Ultrasonic flow meters, particularly the transducer assemblies with impedance matching transformers, are prone to failures due to exposure to extreme temperatures, pressure variations, and corrosive fluids, leading to reliability issues and increased maintenance time.
Innovation Solution
Moving the impedance matching transformers outside the pressure barrier and transducer port, within a short distance from the piezoelectric elements, reduces mechanical stress and exposure to harsh conditions, improving reliability and simplifying troubleshooting and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transformers are placed inside the pressure boundary and transducer port, then electrical connection to piezoelectric elements is direct and compact, but reliability decreases due to exposure to extreme temperatures, pressure variations, and corrosive fluids
Solution Approach 1:
The transformer is extracted from the harsh environment inside the pressure boundary and transducer port, and relocated to a protected external location. This separation removes the transformer from direct exposure to extreme temperatures, pressure variations, and corrosive fluids while maintaining electrical connection to the piezoelectric elements through external wiring.
Solution Approach 2:
An intermediary connection system is introduced between the piezoelectric elements and the transformer. This intermediary consists of external electrical connections that bridge the gap between the internal piezoelectric elements and the external transformer, allowing electrical signal transmission without requiring the transformer to be physically located inside the pressure boundary.
2Ease of repair
If transformers are placed outside the pressure barrier and transducer port, then reliability increases and maintenance is simplified, but the physical distance from piezoelectric elements increases
Solution Approach 1:
The transformer is extracted from the internal environment and positioned externally, which naturally increases the physical distance from the piezoelectric elements. However, this external placement enables easier access for troubleshooting and repair operations, as technicians can directly access and replace the transformer without disassembling internal components or dealing with pressurized environments.
3Duration of action of stationary object
If transformers are located adjacent to piezoelectric crystals, then electrical connection is minimized in length, but mechanical stress and exposure to harsh conditions increase
Solution Approach 1:
The transformer is extracted from the high-stress environment inside the pressure boundary and relocated externally. This removal eliminates exposure to mechanical stress from pressure variations, extreme temperatures, and corrosive fluids, thereby increasing the mean time between failures. The electrical connection length is acceptable given the significant improvement in reliability and durability.
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 configuration increases the mean time between failures, decreases troubleshooting time, and reduces maintenance time for transducer assemblies, enhancing the overall reliability and efficiency of ultrasonic flow meters.
Implementation Method 1
a piezoelectric element in each transducer assembly
Implementation Method 2
Ultrasonic flow meters may be used to measure the amount of fluid flowing in a pipeline
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Ultrasonic flow meter transducer assembly. At least one some of the illustrative embodiment are systems including: a spool piece that defines an exterior surface, a central passage, and a transducer port extending from the exterior surface to the central passage; and a transducer assembly coupled to the transducer port. The transducer assembly includes: a transition element coupled to the spool piece, the transition element having a first end disposed within the transducer port, and a second end residing outside the exterior surface; a piezoelectric module with a piezoelectric element, the piezoelectric module directly coupled to the first end of the transition element and the piezoelectric module disposed within the exterior surface; a transformer module with a transformer disposed therein, the transformer module directly coupled to the second end of the transition element and the transformer module disposed outside the exterior surface; and an electrical conductor disposed within a passage through the transition element, the electrical conductor couples the transformer to the piezoelectric element.