Ultrasonic Water Meter Plastic Enclosure Design
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Solution Overview
Problem
Traditional ultrasonic flow meters are typically housed in metal enclosures, which are not suitable for high-volume manufacturing and do not mimic the appearance of mechanical water meters, limiting their manufacturing and design flexibility.
Innovation Solution
The ultrasonic flow meter is designed with a separate sealed section for electronic parts, using engineering plastics for the flow tube and outer case, allowing for a similar appearance to mechanical water meters while ensuring operation underwater, with features like ultrasonic welding, epoxy resin sealing, and tamper-proofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal enclosures are used for ultrasonic flow meters, then structural strength and sealing are improved, but manufacturing cost and complexity increase, and high-volume manufacturing becomes difficult
Solution Approach 1:
The patent changes the material parameter from metal to engineering plastic, specifically using materials like polypropylene or PVC that can be molded into the required shapes. This allows the enclosure to maintain sufficient structural strength while enabling high-volume manufacturing through injection molding processes, directly resolving the contradiction between strength and ease of manufacture
Solution Approach 2:
The patent employs composite construction by combining engineering plastic for the main enclosure body with separate sealed sections for electronic parts. This composite approach allows different portions of the enclosure to serve different functions - the main body provides structural strength and water resistance, while separate sealed sections protect electronics, achieving both strength requirements and manufacturing ease
2Duration of action of stationary object
If metal enclosures are used, then durability is improved, but appearance similarity to mechanical water meters and design flexibility are reduced
Solution Approach 1:
The patent changes the material aesthetic parameters by using engineering plastics that can be molded to replicate the traditional mechanical water meter appearance. The plastic material can be formed into the characteristic cylindrical shape with measurement markings and display areas, achieving appearance similarity while maintaining durability through proper material selection and sealing design
Solution Approach 2:
The patent effectively copies the appearance and form factor of traditional mechanical water meters using engineering plastic enclosures. By replicating the external shape, measurement markings, and overall configuration of mechanical meters, the ultrasonic flow meter achieves visual similarity while incorporating modern electronic components internally
3Ease of manufacture
If plastics are used for high-volume manufacturing, then manufacturing cost and flexibility are improved, but water resistance and operational integrity when submerged may be compromised
Solution Approach 1:
The patent divides the enclosure into separate sealed sections - one for the flow tube and another for the electronic parts. This segmentation allows each section to be independently sealed and tested for water resistance. The electronic section is specifically designed with enhanced sealing to protect sensitive components while the flow tube section handles water flow, resolving the contradiction between manufacturing ease and water resistance
Solution Approach 2:
The patent employs flexible sealing mechanisms including gaskets, O-rings, and sealed membranes made from elastomeric materials. These flexible sealing elements are integrated into the plastic enclosure to create water-tight barriers that protect electronic components while allowing the plastic body to maintain its molded shape and sealing integrity when submerged
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 design enables efficient, cost-effective, and reliable high-volume manufacturing of ultrasonic flow meters with a durable and water-resistant structure, maintaining operational integrity even when submerged, and providing a tamper-proof mechanism.
Implementation Method 1
An ultrasonic transducer is secured at each end of the flow tube. Each transducer has a direction of maximum sensitivity perpendicular to the long axis of the flow tube.
Implementation Method 2
The two ends are ultrasonically welded to the centre body section
Implementation Method 3
The transducers are fixed into two locating rings on the ends of the tube using an epoxy resin.
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
There is described an ultrasonic flow meter comprising a pipe having two ends, electronic circuitry, a first enclosure housing the electronic circuitry, a second enclosure housing the pipe, and a plurality of ultrasonic transducers attached to an external surface of the pipe in the second enclosure. The first enclosure is watertight, whereas the second enclosure is not watertight. The two ends of the pipe protrude from the second enclosure. Each transducer is covered by a respective cap and sealed from water ingress. Each transducer is connected to the electronic circuitry by a respective pair of wires.