Ultrasonic Flow Meter Mounting Stub for Uniform Weld Alignment
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Solution Overview
Problem
Existing flow measurement systems face challenges in precisely and stably positioning ultrasonic probes in high-pressure environments due to oblique orientations, which often require complex manufacturing and post-processing to ensure uniform weld seams and avoid distortion.
Innovation Solution
A flow measurement system with a mounting stud having a cylindrical surface perpendicular to the channel axis, featuring a circumferential weld seam and spacers/pins for precise alignment, allowing automated welding without mechanical post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the ultrasonic probe is mounted at an oblique angle to achieve the required measuring section, then the flow velocity measurement is enabled, but the weld seam becomes uneven and distortion occurs
Solution Approach 1:
The mounting structure is divided into two functional parts: a perpendicular mounting bracket for welding and an oblique probe holder for measurement. This segmentation allows the welding surface to be perpendicular (ensuring uniform weld seams) while the probe itself can be oriented obliquely (enabling flow velocity measurement through the differential time-of-flight method).
Solution Approach 2:
The mounting bracket acts as an intermediary element between the housing and the ultrasonic probe. It provides a perpendicular mounting surface for welding to the housing, then uses internal positioning features (such as angled recesses or adjustment mechanisms) to orient the probe obliquely. This intermediary structure decouples the welding orientation from the probe orientation, resolving the contradiction between weld quality and measurement capability.
2Ease of operation
If a cylindrical mounting bracket is welded at an angle to the housing, then the ultrasonic probe can be positioned for oblique emission, but extensive rework is necessary due to uneven weld seams and distortion
Solution Approach 1:
The mounting bracket is designed with pre-formed oblique surfaces or recesses that guide the ultrasonic probe into the correct oblique position. This preliminary geometric configuration ensures proper probe orientation without requiring post-weld machining or adjustment, eliminating the need for extensive rework while maintaining easy probe positioning.
3Shape
If forming or casting techniques are used to produce angled nozzles, then the probe mounting angle is achieved, but manufacturing effort increases significantly
Solution Approach 1:
Instead of creating a complex angled nozzle through forming or casting, the invention uses a simple cylindrical mounting bracket that is easier to manufacture. The oblique orientation is achieved by copying the angle requirement into the probe positioning features (such as angled recesses or mechanical guides) rather than into the basic nozzle geometry, significantly reducing manufacturing effort.
4Device complexity
If a bent ultrasonic probe is used to achieve oblique radiation direction, then the mounting alignment is simplified, but the probe cost increases and positioning accuracy decreases
Solution Approach 1:
Instead of using a mechanically complex bent probe that is expensive and difficult to position accurately, the invention replaces the mechanical bending with a geometric solution. The mounting bracket provides precise angular positioning through its designed features (such as angled seating surfaces or positioning pins), allowing a straight, inexpensive probe to achieve the required oblique radiation direction with high positioning accuracy.
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
Ensures accurate and distortion-free positioning of ultrasonic probes, facilitating easy manufacturing and reliable operation under high pressure without the need for additional processing.
Implementation Method 1
at least one ultrasonic probe which can be attached to the housing and which has a direction of emission
Implementation Method 2
flow velocities of fluids in pipelines can be determined using ultrasonic measurement technology based on the differential time-of-flight method
Implementation Method 3
a circumferential weld seam is formed in the transition area between the cylindrical surface of the mounting stub and the outer wall of the housing
Data Source
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AI summary
A flow measurement system for measuring a fluid flow in a fluid line comprises a housing having a fluid channel and defining a channel axis through the course of the fluid channel, and at least one ultrasonic probe that can be attached to the housing and has a direction of radiation, wherein a mounting bracket is provided for attaching the ultrasonic probe to the housing, which is welded to the outer wall of the housing and has a receptacle for the ultrasonic probe, wherein the direction of radiation of the ultrasonic probe is inclined to the channel axis when the ultrasonic probe is arranged in the receptacle.The mounting stub has a cylindrical surface that surrounds a stub axis running perpendicular to the channel axis and extends from a housing-side end region of the mounting stub in the direction of the stub axis, with a circumferential weld seam being formed in the transition area between the cylindrical surface of the mounting stub and the outer wall of the housing.