Ultrasonic Water Meter Sensor Mounting Plate Design
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Solution Overview
Problem
Existing water metering devices face challenges such as complex assembly, high production costs, precision issues due to sensor deformation, and vulnerability to tampering, particularly in ultrasonic sensors mounted below the containment structure.
Innovation Solution
A water meter design featuring a clamping element inside the containment structure that secures sensors without rotating them, using a clamping mechanism to connect the sensor means to the bottom wall, ensuring insulation and tamper resistance without the need for additional potting material, and allowing for quick assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic sensors are mounted on the passage duct below the containment structure (0° position), then assembly is simplified and sped up, but insulation of the inside of the containment structure becomes critical and requires additional potting material
Solution Approach 1:
The patent divides the mounting function into two separate components: a mounting plate that provides mechanical support and positioning, and a separate insulation layer that provides electrical isolation. This segmentation allows each component to be optimized independently - the mounting plate simplifies assembly by providing a flat mounting surface, while the insulation layer can be applied as a separate step without complicating the overall assembly process.
Solution Approach 2:
The mounting plate acts as an intermediary element between the sensor and the containment structure. It provides a stable mounting surface and positioning reference, while also serving as a base for applying the insulation layer. This intermediary component resolves the contradiction by enabling simple assembly (through the plate) while maintaining insulation requirements (through the separate insulating layer).
2Ease of operation
If sensors are mounted below the containment structure, then assembly access is improved, but the plastic bottom is strongly stressed by sensor thrust causing deformation and movement
Solution Approach 1:
The patent separates the mechanical support function from the mounting function. The mounting plate provides a rigid, deformation-free surface for sensor mounting, while the insulation layer provides electrical isolation. This segmentation prevents the sensor thrust from being transmitted to the plastic bottom, eliminating the deformation problem while maintaining easy assembly access.
Solution Approach 2:
The mounting plate serves as a mechanical intermediary that absorbs and distributes the sensor thrust forces, preventing direct transmission to the plastic bottom wall. This intermediary structure eliminates the deformation and movement issues while preserving the assembly access benefits of mounting from below.
3Measurement precision
If sensors are mounted on the passage duct laterally rotated by 90°, then measurement capability is achieved, but assembly becomes particularly complex and laborious
Solution Approach 1:
The patent separates the sensing function from the mounting function by using a dedicated mounting plate. The mounting plate provides a simple, non-rotated mounting interface, while the sensor is positioned on the plate to achieve the required 90° angular orientation for measurement. This segmentation simplifies assembly by eliminating the need to rotate the entire sensor assembly during installation.
Solution Approach 2:
The mounting plate is pre-configured with mounting holes and sensor positioning features that accommodate the required 90° sensor orientation. This preliminary preparation of the mounting plate allows sensors to be installed in the correct angular position without complex rotation operations during assembly, reducing assembly complexity while maintaining measurement capability.
4Reliability
If additional potting material is used for insulation, then insulation of the containment structure is guaranteed, but production costs and assembly time increase
Solution Approach 1:
The patent divides the insulation function from the mounting function by using a separate insulation layer applied to the mounting plate. This segmentation allows the insulation to be applied as a separate, standardized step rather than requiring mixed potting materials during assembly, improving production efficiency while maintaining insulation reliability.
Solution Approach 2:
The patent uses a separate, easily replaceable insulation layer instead of requiring permanent potting material. This approach allows for simpler, more cost-effective insulation that can be applied and removed independently, improving production efficiency while maintaining sufficient insulation reliability for the application.
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 design enables efficient, precise, and cost-effective manufacturing with enhanced security against tampering, reducing assembly time and complexity while maintaining measurement accuracy.
Implementation Method 1
at least one clamping element housed inside said housing volume of said containment structure so as not to be accessible from the outside of said containment structure: sensor means which are structurally distinct from said at least one clamping element and which are configured to measure at least one flow rate and/or flow of the fluid passing through the duct of said unit
Implementation Method 2
at least one containing structure, internally defining a housing volume and comprising a bottom wall... the containment structure being leakproof to prevent the outward leakage of liquid and/or the ingress of liquid from the outside into the interior of the housing volume
Implementation Method 3
In the case of ultrasonic measuring devices, at least two ultrasonic sensors are mounted on or in correspondence with said water passage duct, in particular at least one ultrasonic emitter and at least one ultrasonic receiver
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
Device (1) for measuring a fluid, preferably a liquid, in particular of the type suitable for measuring the flow rate and/or flow of a fluid circulating inside a duct and through the device itself, characterized by the fact of comprising: - at least one containment structure (2), internally defining a housing volume (3) and comprising a bottom wall (4), which is provided with a first surface facing internally with respect to said housing volume (3) and a second surface facing externally with respect to said housing volume (3); - at least one unit (5) for the passage of said fluid, comprising: - a duct (50) internally delimiting a path (5') extending along a flow direction (X) between an inlet port (6) for said fluid and an outlet opening (7) for said fluid, and - at least one abutment portion (8) which can be mechanically connected to said bottom wall (4) of said containment structure (2) at said second surface; - clamping element (10) which is housed inside said housing volume (3) of said containment structure (2) so as not to be accessible from the outside of said containment structure (2); - sensor means (11) which are configured to measure at least one flow rate and/or flow of the fluid passing through the duct (50) of said unit (5), and characterized by the fact that: - said bottom wall (4) is clamped between said clamping element (10) and said abutment portion (8) of said unit (5), said sensor means (11) are mounted, entirely or for the most part, in corresponding seats (12) obtained in said at least one abutment portion (8) of the unit (5) for the passage of said fluid and being blocked inside the corresponding seats (12) by said bottom wall (4) of said containment structure (2) and/or by said at least one clamping element (10).