Description:FIELD OF INVENTION
[0001] The embodiments of the present disclosure generally relate to flowmeters. More particularly, the present disclosure relates to a modular ultrasonic water flowmeter with an electronic closure.

BACKGROUND OF THE INVENTION
[0002] The following description of the related art is intended to provide background information pertaining to the field of disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section is used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of the prior art.
[0003] For conventional ultrasonic water flowmeters, ensuring a reliable design that provides a product lifespan of up to 5 years under diverse environmental conditions remains a significant challenge. Additionally, growing customer demands for compatibility with various communication protocols, such as GSM, LoRaWAN, Bluetooth, and RS485, have created a need for modular designs that can accommodate emerging technologies. The domestic, commercial, and industrial markets require water flowmeters in a range of DN (diameter nominal) sizes. However, manufacturing unique components for each DN size significantly increases costs, making scalability a key challenge. Currently, most technologies rely on potting solutions to protect PCBs (Printed Circuit Boards) from dust and moisture. Hard potting, a commonly used method, involves encapsulating the PCB in a hard resin, creating a robust but irreversible seal. This poses several limitations. Once the resin cures, access to the PCB is permanently restricted, complicating the assembly process where frequent access is needed for testing via wired connectors. Hard-potted PCBs cannot be reused or repurposed, meaning that if the PCB components fail or reach the end of their lifecycle, they must be discarded entirely, leading to waste and higher costs. In contrast, soft potting offers more flexibility but is significantly more expensive. Therefore, addressing these challenges through innovative, cost-effective, and modular solutions is crucial for meeting market demands while ensuring durability and adaptability.
[0004] There is, therefore, a need in the art to overcome the shortcomings of the existing prior arts.

OBJECTS OF THE PRESENT DISCLOSURE
[0005] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.
[0006] An object of the present disclosure is to provide a modular ultrasonic water flowmeter with identical internal components for multiple DN sizes (DN15, DN20, DN25, DN32, DN40, DN50, and DN65), ensuring easy scalability and reduced manufacturing complexity.
[0007] An object of the present disclosure is to provide a modular ultrasonic water flowmeter to minimize production costs by reducing the number of unique parts required, enabling mass production with fewer molds and simplified assembly processes.
[0008] An object of the present disclosure is to provide a modular ultrasonic water flowmeter to achieve hermetic sealing with IP68 compliance using ultrasonic welding, ensuring robustness in harsh environmental and high-pressure conditions without the need for fasteners.
[0009] An object of the present disclosure is to provide a modular ultrasonic water flowmeter to accommodate both battery-operated and externally powered configurations, providing adaptability for various applications, including remote and urban areas.
[0010] An object of the present disclosure is to provide a modular ultrasonic water flowmeter that integrates a transparent top cover for clear visibility of the LCD screen and support IR communication for data logging and diagnostics, enhancing usability and functionality.

SUMMARY
[0011] This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.
[0012] In an aspect of the present disclosure, a modular ultrasonic water flowmeter is disclosed. The modular ultrasonic water flowmeter includes a primary casing body configured to house an electronic enclosure. The modular ultrasonic water flowmeter further includes two ultrasonic transducers isolated from water pressure via gaskets. The modular ultrasonic water flowmeter further includes a top cover hermetically sealed to the primary casing body using ultrasonic welding and a reflector assembly positioned within a pipe of the primary casing body for transmitting ultrasonic signals between the two ultrasonic transducers, and identical internal assembly components enabling compatibility across multiple DN sizes, including DN15, DN20, DN25, DN32, DN40, DN50, and DN65.
[0013] In an aspect of the present disclosure, a method of assembling the modular ultrasonic water flowmeter is disclosed. The method begins with joining the primary casing body and the top cover using ultrasonic welding to provide a fastener-free assembly. The method ends with enabling hermetic sealing that complies with IP68 standards for protection against dust and water ingress.

BRIEF DESCRIPTION OF DRAWINGS
[0014] The accompanying drawings, which are incorporated herein, and constitute a part of this disclosure, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that invention of such drawings includes the disclosure of electrical components, electronic components or circuitry commonly used to implement such components.
[0015] FIG. 1 illustrates (a) an exemplary architecture of the modular ultrasonic water flowmeter, (b) a transducer assembly employed in the proposed modular ultrasonic water flowmeter, and (c) hinge cap, in accordance with an embodiment of the present disclosure.
[0016] FIG. 2 illustrates an exemplary architecture of the fluid flow measuring device with different pipe sizes (a) DN15, (b) DN20, (c) DN25, (d) DN32, (e) DN40, (f) DN50 and (g) DN65 with (i) side view, (ii) front view, and (iii) top view, in accordance with an embodiment of the present disclosure
[0017] FIG. 3 illustrates an exemplary flow diagram representation of the proposed method of assembling the modular ultrasonic water flowmeter, in accordance with an embodiment of the present disclosure.
[0018] FIG. 4 illustrates an exemplary representation of how the battery slider is assembled to the PCB mounting unit in the proposed modular ultrasonic water flowmeter, in accordance with an embodiment of the present disclosure.
[0019] The foregoing shall be more apparent from the following more detailed description of the disclosure.

DETAILED DESCRIPTION OF INVENTION
[0020] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
[0021] In an embodiment of the present disclosure, a modular ultrasonic water flowmeter is disclosed. The modular ultrasonic water flowmeter includes a primary casing body configured to house an electronic enclosure. The modular ultrasonic water flowmeter further includes two ultrasonic transducers isolated from water pressure via gaskets. The modular ultrasonic water flowmeter further includes a top cover hermetically sealed to the primary casing body using ultrasonic welding and a reflector assembly positioned within a pipe of the primary casing body for transmitting ultrasonic signals between the two ultrasonic transducers, and identical internal assembly components enabling compatibility across multiple DN sizes, including DN15, DN20, DN25, DN32, DN40, DN50, and DN65.
[0022] In an embodiment, the electronic enclosure is configured to support modular power configurations, including battery-operated devices with a sliding battery housing mechanism and externally powered devices with an integrated PCB mount.
[0023] In an embodiment, the sliding battery housing mechanism is configured to securely hold 1C or 3C batteries and integrates with the PCB mount through an interference fit, eliminating the need for additional fasteners.
[0024] In an embodiment, the PCB mount comprises four mounting bosses for securely attaching a PCB unit using fasteners to ensure precise positioning of electronic components within the enclosure
[0025] In an embodiment, the reflector assembly is positioned and secured within the flow pipe using an internal locking mechanism to enable effective signal transmission between the ultrasonic transducers for accurate flow measurement.
[0026] In an embodiment, the top cover includes an overmolded transparent polycarbonate material that provides visual access to an LCD screen and facilitates IR communication for remote operation and diagnostics.
[0027] In an embodiment, the primary casing body comprises variations for external cable outputs, selected from a single outlet hole, two outlet holes, and a sealed configuration with no outlet holes, each configured with a PG gland for secure cable assembly.
[0028] In an embodiment, the top cover is provided with a hinge cap for protection of the top cover.
[0029] In an embodiment of the present disclosure, a method of assembling the modular ultrasonic water flowmeter is disclosed. The method begins with joining the primary casing body and the top cover using ultrasonic welding to provide a fastener-free assembly. The method ends with enabling hermetic sealing that complies with IP68 standards for protection against dust and water ingress.
[0030] The various embodiments throughout the disclosure will be explained in more detail with reference to FIG.s 1-4.
[0031] Illustrated in FIG. 1(a) is an exemplary architecture of the modular ultrasonic water flowmeter 100. The modular ultrasonic water flowmeter 100 may include a fluid flow pipe 102. The fluid flow pipe 102 may be configured to enable the flow of a fluid. The fluid flow pipe 102 may include a first end 102-1 including a first piping thread 102-11 and a second end 102-2 including a second piping thread 102-21. The first piping thread 102-11 and the second piping thread 102-21 may allow the flow of the fluid through the fluid flow pipe 102 providing a leakproof connection.
[0032] In an embodiment, the modular ultrasonic water flowmeter 100 may include a casing body 104 coupled to the fluid flow pipe 102. The casing body 104 may be configured to act as a housing for a plurality of functional components employed to measure the flow of the fluid flowing through the fluid flow pipe 102. The casing body 104 is sealed tamperproof with a top cover 110 by using a sealing technique to protect the plurality of functional components from an environmental damage.
[0033] In an embodiment, the casing body 104 may include a plurality of external cable outlets. The plurality of external cable outlets can include, but not limited to: a single outlet hole, a two-outlet hole, a no hole, and the like 124. The casing body 104 may be configured to couple with the fluid flow pipe 102 of a plurality of pipe sizes. The plurality of pipe sizes can include, but not limited to: a DN15, a DN20, a DN25, a DN32, a DN40, a DN50, a DN65, and the like.
[0034] In an exemplary embodiment, the casing body 104 may include three variations for external cable outlet with the single outlet hole 124 or with 2 outlet holes, and with no holes. The external cable outlet present may be assembled using a standard PG gland.
[0035] In an embodiment, the modular ultrasonic water flowmeter 100 may be configured to securely seal the plurality of functional components based on an integrated enclosure approach in combination with the sealing technique to enable measurement of the flow of the fluid flowing through the fluid flow pipe 102.
[0036] In an embodiment, the plurality of functional components can include, but not limited to: a plurality of transducers, a plurality of gaskets, a multi-battery, a battery 106, a plurality of Printed Circuit Board (PCB) units, a PCB mounting unit 108, a Liquid Crystal Display (LCD) screen, a plurality of Infrared (IR) communication modules, and the like. The plurality of functional components employed in the modular ultrasonic water flowmeter 100 adaptable with the plurality of pipe sizes are common except the casing body 104 and the reflector assembly.
[0037] In an embodiment, the integrated enclosure approach may be configured to provide a hermetic sealing under a high pressure of water and at a depth of at least 10m. The integrated enclosure approach enables the integration of the plurality of functional components into the casing body 104 and enclosing the casing body 104 employing the combination of the top cover 110 and a hinge cap 112. The hinge cap 112 can be configured to serve as a protective layer over the top cover 110 to provide protection from the environmental damage. The environmental damage can include, but not limited to: a dust, a moisture, a corrosion, and the like.
[0038] In an embodiment, the sealing technique uses ultrasonic welding to achieve multiple functions. The functions include creating a hermetic seal to ensure the enclosure is airtight and waterproof, providing protection against environmental factors. Another function is to reduce the need for PCB encapsulation material that eliminates or minimizes the requirement for additional protective coatings or materials for the PCB, thereby lowering material costs. Yet another function is to reduce assembly time. The fast and efficient ultrasonic welding process speeds up the assembly of the modular ultrasonic water flowmeter 100. The ultrasonic welding method is compatible with different pipe sizes and uses a common welding horn. This shared tool reduces manufacturing complexity and further contributes to cost savings by simplifying the production process.
[0039] In an exemplary embodiment, the ultrasonic welding technique may enable fastener-free assembly, while providing the hermetic sealing for IP68 and adobe conditions. The IP68 is an Ingress Protection (IP) rating that indicates a device is dust-tight and can withstand water immersion.
[0040] In an embodiment, the top cover 110 may include a transparent overmolded polycarbonate section 122 configured to provide a clear visibility of the plurality of functional components and enable wireless monitoring and interaction. The top cover 110 part is welded to the casing body 104 employing the sealing technique.
[0041] In an exemplary embodiment, the overmolded polycarbonate component 122 may give visual access to the LCD screen and IR communication modules.
[0042] In an embodiment, the PCB mounting unit 108 can be integrated into the casing body 104 employing a mounting boss by employing a fastener. The battery 106 may be integrated into the casing body 104 to enable the positioning of the multi-battery and the battery 106 can be eliminated from the casing body 104 for the fluid flow measuring device 100 powered by an external source.
[0043] In an exemplary embodiment, the casing body 104 may include four mounting bosses allowing for the positioning of the PCB mounting unit 108 using fasteners. The battery 106 is a sliding mechanism employed in the housing of the battery assembly which can hold 1C batteries, 3C batteries, and the like to assemble with the PCB mount. The entire battery assembly may be locked in place using an interference fit with the casing body 104.
[0044] In an embodiment, the fluid flow pipe 102 has provision to encase a reflector assembly configured to transmit a signal between the plurality of transducers. The reflector assembly is inserted from an inlet side of the fluid flow pipe 102 and locked in place using a screw inside the casing body 104. The reflector assembly can be configured to transmit the signals from the transducers to each other.
[0045] In an exemplary embodiment, the modular ultrasonic water flowmeter 100 with the casing body may enable modularity for accommodating battery-operated and externally powered PCBs. Further, the modular ultrasonic water flowmeter 100 with the casing body may reduce the number of manufactured parts once presented across different DN sizes of water meters including, but not limited to: DN15, DN20, DN25, DN32, DN40, DN50 & DN65, and the like while retaining identical functional components and internal assembly parts, thereby enabling easy scalability to every size while reducing the cost of manufacturing. Further, modular ultrasonic water flowmeter 100 with the casing body may be employed across the smallest pipe to the biggest pipe sizes. In an instance, the fluid flow measuring device is a water flowmeter. In still another instance, the PCB components, the battery, the fasteners, the top lid, and the hinge cover are repeated across the modular ultrasonic water flowmeter in all the pipe sizes.
[0046] Illustrated in FIG. 1(b) is a representation 100b of a transducer assembly employed in the proposed fluid flow measuring device 100. The casing body 104 may be configured to enclose a plurality of transducers 114 with gaskets 116 that isolate the pressure of the fluid flowing within the fluid flow pipe 102. A mounting plate 118 with a plurality of screws 120 may be employed to securely fix the transducers 114 inside the casing body 104.
[0047] In an exemplary embodiment, the two transducers 114-1 and 114-2 may be housed with gaskets 116-1 and 116-2 through the mounting plate 118 employing the screws 120-1, 120-2, 120-3, and 120-4, that isolate the pressure of the water flowing within the pipe. The casing body 104 may include a provision to seal the high-pressure zone using a minimal volume of hard potting material. The hard potting material may include, but not limited to: an epoxy, a polyurethane, a silicone encapsulation material, and the like.
[0048] Illustrated in FIG. 1(c) is a representation 100c of the hinge cap 112 of the fluid flow measuring device 100. The hinge cap 112 is configured to be opened and closed for operating the fluid flow measuring device 100.
[0049] FIG. 2 illustrates an exemplary architecture of the fluid flow measuring device 100 with different pipe sizes (a) DN15, (b) DN20, (c) DN25, (d) DN32, (e) DN40, (f) DN50 and (g) DN65 with (i) side view, (ii) front view, and (iii) top view, in accordance with an embodiment of the present disclosure.
[0050] In an embodiment, referring to FIG.2, the exemplary architecture 200 of the modular ultrasonic water flowmeter 100 with different pipe sizes (a) DN15, (b) DN20, (c) DN25, (d) DN32, (e) DN40, (f) DN50 and (g) DN65 with (i) side view, (ii) front view, and (iii) top view. The modular ultrasonic water flowmeter 100 architecture can be common for the functional components for the pipe sizes from DN15 to DN65, which reduces the number of parts leading to less expensive manufacturing.
[0051] In an exemplary embodiment, referring to FIG. 2(a), the DN15 modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of a nominal diameter of 15 millimetres that can be employable with pipe systems with a DN of 15mm. The DN15 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery 106, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the plurality of Infrared (IR) communication modules enclosed inside the casing body 104.
[0052] In an exemplary embodiment, referring to FIG. 2(b), the DN20 modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of the nominal diameter of 20 millimetres that can be employable with pipe systems with a DN of 20mm. The DN20 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery slider, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the Infrared (IR) communication modules enclosed inside the casing body 104.
[0053] In an exemplary embodiment, referring to FIG. 2(c), the modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of a nominal diameter of 25 millimetres that can be employable with pipe systems with a DN of 25mm. The DN25 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery slider, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the Infrared (IR) communication modules enclosed inside the casing body 104.
[0054] In an exemplary embodiment, referring to FIG. 2(d), the DN32 modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of a nominal diameter of 32 millimetres that can be employable with pipe systems with a DN of 32mm. The DN32 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery slider, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the Infrared (IR) communication modules enclosed inside the casing body 104.
[0055] In an exemplary embodiment, referring to FIG. 2(e), the DN40 modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of a nominal diameter of 40 millimeters that can be employable with pipe systems with a DN of 40mm. The DN40 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery slider, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the Infrared (IR) communication modules enclosed inside the casing body 104.
[0056] In an exemplary embodiment, referring to FIG. 2(f), the DN50 modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of a nominal diameter of 50 millimetres that can be employable with pipe systems with a DN of 50 mm. The DN50 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery slider, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the Infrared (IR) communication modules enclosed inside the casing body 104.
[0057] In an exemplary embodiment, referring to FIG. 2(g), the DN65 modular ultrasonic water flowmeter may include the casing body 104 that can be coupled to the fluid flow pipe 102 with the size of a nominal diameter of 65 millimetres that can be employable with pipe systems with a DN of 65mm. The DN65 modular ultrasonic water flowmeter may include the functional components including, but not limited to: the transducers, the gaskets, the multi-battery, the battery slider, the Printed Circuit Board (PCB) units, the PCB mounting unit, the Liquid Crystal Display (LCD) screen, and the Infrared (IR) communication modules enclosed inside the casing body 104.
[0058] In an exemplary embodiment, apart from the casing body 104 and the reflector assembly, the functional components are common across the DN15 fluid flow measuring device, the DN20 fluid flow measuring device, the DN25 fluid flow measuring device, the DN32 fluid flow measuring device, the DN40 fluid flow measuring device, the DN50 fluid flow measuring device, and the DN65 fluid flow measuring device.
[0059] FIG. 3 illustrates an exemplary flow diagram representation of the proposed method of assembling the modular ultrasonic water flowmeter, in accordance with an embodiment of the present disclosure.
[0060] Illustrated in FIG. 3 is a method 300 of assembling the modular ultrasonic water flowmeter 100. The method 300 begins with joining 302 the primary casing body 104 and the top cover 110 using ultrasonic welding to provide a fastener-free assembly. The method 300 ends with enabling 304 hermetic sealing that complies with IP68 standards for protection against dust and water ingress.
[0061] In an embodiment of the present disclosure, the method 300 of assembling the modular ultrasonic water flowmeter 100 starts with the preparation of the primary casing body (104) and the top cover (110), ensuring all components are clean and free from contaminants. The primary casing body (104), designed to house internal components such as the transducers, the reflector assembly, and the PCBs, is first inspected to confirm proper placement of the gaskets for water pressure isolation. The reflector assembly is inserted from the inlet side of the primary casing body 104 and locked in place using an internal screw, ensuring accurate alignment for signal transmission. Next, the PCB mounting unit is installed, secured by four mounting bosses in the casing body, and fastened to provide a stable platform for electronic components. Thereafter, the battery slider is fitted into the primary casing body 104, ensuring a precise sliding mechanism that locks into place with an interference fit. Once the internal assembly is complete, the top cover 110, which features a transparent polycarbonate overmolded component 122 for LCD screen visibility and IR communication, is aligned with the casing body. The components are then joined using ultrasonic welding, a process that uses high-frequency vibrations to generate heat at the interface, fusing the two parts without the need for fasteners. This welding step ensures a permanent bond and eliminates mechanical weaknesses typically caused by screws or adhesives. The ultrasonic welding also enables precise alignment and uniform sealing, critical for the functionality of the device. The welded joint creates a hermetic seal, preventing dust, moisture, and water ingress into the enclosure. After welding, the assembly is inspected to ensure proper alignment of the top cover with the primary casing body 104, verifying that the LCD screen and IR communication modules remain fully visible. The hinge cap 112 is then attached over the top cover 110, providing additional protection and enhancing the aesthetic appeal of the modular ultrasonic water flowmeter 100. For externally powered variants, PG glands are used to seal any external cable outlets, ensuring continuity in IP68 compliance. The assembled flowmeter is then tested for water and dust ingress, confirming that the hermetic sealing meets IP68 standards. This ensures the device is capable of withstanding prolonged submersion in water and operation in dusty environments. In the end, the assembled flowmeter undergoes functional testing to validate the performance of ultrasonic transducers, signal reflectors, and electronic components. For battery-operated models, battery functionality and interference fits are checked, while externally powered models are tested for electrical connections. The completed assembly is inspected for quality, ensuring it meets design specifications and operates reliably across varying pipe sizes (DN15 to DN65).
[0062] FIG. 4 illustrates an exemplary representation of how the battery slider is assembled to the PCB mounting unit in the proposed modular ultrasonic water flowmeter, in accordance with an embodiment of the present disclosure.
[0063] Illustrated in FG. 4 is a representation 400 of how the battery slider is assembled to the PCB mounting unit 108 in the proposed modular ultrasonic water flowmeter 100. First, the PCB mounting unit 108, which features four mounting bosses, is attached to the primary casing body 104 and secured with fasteners to create a stable foundation for the electronic components. The battery slider, designed to hold either 1C or 3C batteries, is prepared by ensuring the battery compartment is clean and the sliding mechanism functions smoothly. The batteries 106 are then inserted into the slider, with proper attention to polarity alignment to avoid operational issues.
[0064] Once the battery slider is prepared, the battery slider is aligned with the guides or slots on the PCB mounting unit 108, ensuring the sliding mechanism is positioned correctly for smooth integration. The battery slider is carefully inserted along these guides, maintaining a tight fit to prevent any wobbling or misalignment. The interference fit between the battery slider and the primary casing body 104 ensures a secure connection, locking the slider into place once it reaches its final position. This tight fit eliminates the need for additional fasteners, simplifying assembly and reducing manufacturing complexity. The interference fit also ensures that the slider remains stable during device operation, even in environments with vibrations or pressure changes. After the battery slider is fully assembled, the assembly is inspected to confirm proper alignment and secure fitting.
[0065] For battery-operated configurations, the battery slider is essential to the modular design, enabling easy replacement or maintenance of batteries without disrupting other components. The assembly process ensures a robust and efficient connection between the battery slider and the PCB mounting unit 108, supporting reliable power delivery and enhancing the flowmeter’s functionality.
[0066] In an embodiment of the present disclosure, the design of the modular ultrasonic water flowmeter is structured to standardize the integrated enclosure across all pipe sizes, ranging from the smallest (DN15) to the largest (DN65). This ensures that critical components such as the PCB, battery, fasteners, top lid, and protective cover are identical for all variants, promoting consistency and compatibility. By employing this integrated design approach, the manufacturing process is greatly simplified, as the same set of components can be used across all pipe sizes. This uniformity reduces the need for multiple molds, tooling, and specialized parts, offering significant cost savings.
[0067] In addition to streamlining production, this approach minimizes inventory requirements, as a single batch of components can cater to multiple pipe sizes. Assembly processes are also simplified since workers only need to be trained on a single standardized procedure, regardless of the pipe size. The top cover, which seals the integrated enclosure, is welded using an ultrasonic welding technique. This welding process provides a robust and fastener-free assembly while ensuring hermetic sealing that complies with IP68 standards, protecting the device against water and dust ingress. The key lies in the use of a common ultrasonic welding horn, which can be used for all pipe sizes. This eliminates the need for separate welding tools for each variant, further reducing manufacturing complexity and costs. The ultrasonic welding not only ensures a uniform, high-quality seal across all models but also shortens the assembly time, boosting production efficiency. The use of a common design for critical components also simplifies the maintenance and repair process, as spare parts are interchangeable across all sizes.
[0068] By adopting this standardized design and welding process, the invention achieves exceptional economic value for manufacturers while ensuring high performance and reliability for end users. It supports scalability, allowing the same core design to be easily adapted to varying application requirements. The compatibility of components across pipe sizes demonstrates the robustness of the design, ensuring that functionality is retained regardless of the specific size or configuration. Ultimately, the combination of standardized components and ultrasonic welding enhances the cost-effectiveness, durability, and versatility of the water flowmeter, making it a highly practical solution for diverse applications
[0069] As can be understood by those ordinary skill in the art, although FIG. 1 shows exemplary components of the modular ultrasonic water flowmeter 100, in different embodiments, the modular ultrasonic water flowmeter 100 may include fewer components, different components, differently arranged components, or additional functional components than depicted in FIG. 1. Additionally, or alternatively, one or more components of the modular ultrasonic water flowmeter 100 may perform functions described as being performed by one or more other components of the modular ultrasonic water flowmeter 100.
[0070] While considerable emphasis has been placed herein on the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter to be implemented merely as illustrative of the disclosure and not as limitation.

ADVANTAGES OF THE PRESENT DISCLOSURE
[0071] The modular ultrasonic water flowmeter uses a standardized internal assembly for various DN sizes (DN15 to DN65), allowing easy scalability without the need for redesigning components. This reduces production complexity and costs while enabling quick adaptation to different pipe sizes.
[0072] The modular ultrasonic water flowmeter minimizes the number of unique parts and uses ultrasonic welding to eliminate fasteners, reducing material costs and simplifying assembly. The shared ultrasonic welding horn further contributes to cost savings by accommodating all pipe sizes with a single tool.
[0073] The ultrasonic welding technique ensures hermetic sealing, providing IP68-rated protection against water and dust ingress. This robust sealing enhances the device’s longevity and reliability, making it suitable for harsh environmental conditions.
[0074] The modular design supports both battery-operated and externally powered configurations, catering to diverse use cases. Components like the Battery Slider can be included or omitted as needed, demonstrating flexibility in adapting to power requirements.
[0075] The fastener-free assembly enabled by ultrasonic welding reduces assembly time and simplifies the manufacturing process. The modularity also allows for easy disassembly, facilitating maintenance and replacement of components such as batteries or PCBs without affecting other parts of the device.
, Claims:1. A modular ultrasonic water flowmeter (100), comprising:
a primary casing body (104) configured to house an electronic enclosure,
two ultrasonic transducers isolated from water pressure via gaskets,
a top cover (110) hermetically sealed to the primary casing body (104) using ultrasonic welding,
a reflector assembly positioned within a pipe (102) of the primary casing body (104) for transmitting ultrasonic signals between the two ultrasonic transducers, and
identical internal assembly components enabling compatibility across multiple DN sizes, including DN15, DN20, DN25, DN32, DN40, DN50, and DN65.
2. A modular ultrasonic water flowmeter as claimed in claim 1, wherein the electronic enclosure is configured to support modular power configurations, including battery-operated devices with a sliding battery housing mechanism and externally powered devices with an integrated PCB mount.
3. A modular ultrasonic water flowmeter as claimed in claim 2, wherein the sliding battery housing mechanism is configured to securely hold 1C or 3C batteries and integrates with the PCB mount through an interference fit, eliminating the need for additional fasteners.
4. A modular ultrasonic water flowmeter as claimed in claim 2, wherein the PCB mount comprises four mounting bosses for securely attaching a PCB unit using fasteners to ensure precise positioning of electronic components within the enclosure
5. A modular ultrasonic water flowmeter as claimed in claim 1, wherein the reflector assembly is positioned and secured within the flow pipe using an internal locking mechanism to enable effective signal transmission between the ultrasonic transducers for accurate flow measurement.
6. A modular ultrasonic water flowmeter as claimed in claim 1, wherein the top cover (110) includes an overmolded transparent polycarbonate component (122) that provides visual access to an LCD screen and facilitates IR communication for remote operation and diagnostics.
7. A modular ultrasonic water flowmeter as claimed in claim 1, wherein the primary casing body (104) comprises variations for external cable outputs, selected from a single outlet hole (124), two outlet holes, and a sealed configuration with no outlet holes, each configured with a PG gland for secure cable assembly.
8. A modular ultrasonic water flowmeter as claimed in claim 1, wherein the top cover (110) is provided with a hinge cap (112) for protection of the top cover (110).
9. A modular ultrasonic water flowmeter as claimed in claim 1, wherein the reflector assembly is inserted through a pipe inlet and locked in position using a screw housed within the primary casing body (104), preventing displacement during operation.
10. A method (300) of assembling a modular ultrasonic water flowmeter, the method (300) comprising steps of:
joining a primary casing body (104) and a top cover (110) using ultrasonic welding to provide a fastener-free assembly, and
enabling hermetic sealing that complies with IP68 standards for protection against dust and water ingress.