Ultrasonic Flow Sensor Mounting via Polygonal Clamp
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Solution Overview
Problem
Existing ultrasonic flow measurement devices face challenges with secure attachment of sensors in pipe sections, leading to measurement inaccuracies due to pressure and temperature fluctuations, and potential corrosion in humid environments, especially when using powder-coated tubes.
Innovation Solution
A thread-free holding element with a polygonal cross-section is used to securely fasten ultrasonic sensors within the pipe, avoiding screw connections and maintaining sensor position under fluid pressure without transmitting stresses, and preventing corrosion by eliminating the need for additional openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic sensors are inserted into openings in the measuring tube to avoid signal attenuation, then measurement precision is improved, but the sensors are exposed to fluid pressure and temperature fluctuations causing measurement deviations
Solution Approach 1:
The device separates the ultrasonic sensor from the fluid environment by using a clamp-on arrangement with coupling elements that contact the pipe wall at multiple discrete points, isolating the sensor while maintaining acoustic coupling through the pipe wall
Solution Approach 2:
The pipe wall itself serves as an intermediary medium, allowing acoustic signals to pass through while physically isolating the ultrasonic sensor from direct contact with the fluid, its pressure, and temperature fluctuations
2Stability of the object's composition
If ultrasonic sensors are screwed into the measuring tube using thread connections, then the sensors are securely held in position, but stresses and temperature/pressure fluctuations are transmitted to the sensor causing measurement deviations
Solution Approach 1:
The invention removes the threaded connection from the measuring tube entirely, extracting the source of stress transmission while maintaining secure sensor positioning through alternative clamp-on mounting mechanisms that do not involve threading into the tube wall
Solution Approach 2:
The coupling elements are designed to contact only specific local areas of the pipe wall, concentrating the mechanical connection at discrete points that do not transmit fluid-induced stresses to the sensor, while maintaining adequate acoustic coupling
3Strength
If screw connections are used to mount ultrasonic sensors on powder-coated measuring tubes, then secure attachment is achieved, but the powder coating is damaged leading to corrosion in humid environments
Solution Approach 1:
The threaded opening and screw connection are completely removed from the design, eliminating the source of coating damage while alternative clamp-on mounting methods provide adequate attachment strength without penetrating or scratching the powder coating
Solution Approach 2:
The coupling elements are designed to wrap around or clamp onto the external surface of the pipe, maintaining attachment through friction and normal contact forces without requiring penetration of the protective powder coating layer
4Ease of manufacture
If clamp-on measuring devices are used to attach ultrasonic sensors to the outside of the measuring tube, then ease of implementation is improved, but signal attenuation occurs due to transmission through the pipe wall
Solution Approach 1:
The coupling elements are designed to contact the pipe wall at multiple specific locations with optimized contact pressure and area, ensuring adequate acoustic signal transmission through the pipe wall while maintaining the simple clamp-on installation approach
Solution Approach 2:
The mounting and acoustic coupling functions are merged into a single integrated clamp-on arrangement, where the same coupling elements that attach the sensor to the pipe also serve as the acoustic transmission path, eliminating the need for separate mounting hardware
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 ensures accurate and reliable flow measurements by maintaining sensor position and preventing corrosion, even in humid conditions, with increased contact surface for counterforce and symmetrical force distribution.
Implementation Method 1
determining the flow rate of a fluid flowing through a pipe section using ultrasonic sensors according to the transit-time difference method
Implementation Method 2
acoustic signals are coupled into a measuring tube by means of an ultrasonic sensor
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a measurement device for determining the flow of a fluid flowing through a pipe section, comprising a measurement pipe (12; 112) having a pipe wall (14), at least one ultrasound sensor (18, 20; 116) for transmitting an acoustic signal and/or receiving an acoustic signal, having an ultrasound sensor upper side (21) and a holding element (22), wherein at least one opening of a first type (28; 116), into which the at least one ultrasound sensor (18, 20; 116) is able to be inserted, is provided in the pipe wall (24), and wherein the measurement device (10; 110) has a mounted state in which the holding element (22) grasps the measurement pipe (12; 112) in a circular manner and bears externally on the at least one ultrasound sensor (18, 20; 116) inserted into the opening of a first type (28; 116).