Abstract: A flow meter includes a pair of ultrasonic transducers. Each transducer includes a housing, a piezoelectric crystal disposed within the housing, and a mini-horn array coupled to the housing. The mini-horn array, which may be formed via a 3D printing technique, includes an opening-free enclosure, a closed cavity inside the enclosure, and a plurality of horns enclosed within the closed cavity. The horns include a horn base portion adjacent to a proximal end surface of the cavity and a horn neck portion that extends from the base portion in a direction away from the piezoelectric crystal and towards a distal end surface of the cavity. The horn neck portions are separated by spaces within the cavity, wherein the spaces between the horn necks may be filled with powder.

Abstract: A flow meter includes a pair of ultrasonic transducers. Each transducer includes a housing, a piezoelectric crystal disposed within the housing, and a mini-horn array coupled to the housing. The mini-horn array, which may be formed via a 3D printing technique, includes an opening-free enclosure, a closed cavity inside the enclosure, and a plurality of horns enclosed within the closed cavity. The horns include a horn base portion adjacent to a proximal end surface of the cavity and a horn neck portion that extends from the base portion in a direction away from the piezoelectric crystal and towards a distal end surface of the cavity. The horn neck portions are separated by spaces within the cavity, wherein the spaces between the horn necks may be filled with powder.

Abstract: Methods and systems for detecting deposit buildup within an ultrasonic flow meter are disclosed. At least some of the illustrative embodiments are ultrasonic flow meters comprising a spool piece configured to couple within a flow of fluid, a first transducer pair mechanically mounted to the spool piece and configured to fluidly couple to the flow of fluids (wherein the first transducer pair comprises an upstream transducer and a downstream transducer in operational relationship to the upstream transducer and defines a first chord there between), and electronics electrically coupled to the first transducer pair. The electronics is configured to detect deposit buildup over an inner surface of the ultrasonic flow meter.

Abstract: Detecting liquid in an acoustic flow meter. At least some of the illustrative embodiments are methods including flowing a gaseous substance through a central passage of a meter body, sending acoustic signals along respective chordal pathways across the central passage (none of the chordal pathways intersect a lower portion of the central passage where liquid, if present during flow of the gaseous substance, accumulates), calculating a flow velocity of the gaseous substance proximate to each chordal pathway based on transit times of the acoustic signals along the respective chordal pathways, and determining the presence of a liquid accumulated in the lower portion based on the flow velocity proximate to each chordal pathway.

Abstract: An embodiment of a piezoelectric assembly for an ultrasonic flow meter comprises a piezoelectric element including a first face and a second face. In addition, the piezoelectric assembly comprises a first electrode engaging the first face. Further, the piezoelectric assembly comprises a second electrode engaging the second face. Still further, the piezoelectric assembly comprises an electrically conductive shim connector attached to the first electrode. Moreover, the piezoelectric assembly comprises a first wire electrically coupled to the shim connector.

Abstract: Determining a pattern of arrival time cycle skip in an acoustic flow meter. At least some of the illustrative embodiments are methods comprising transceiving acoustic signals through a fluid flowing in a meter (the transceiving between respective pairs of a plurality of transducer pairs), measuring transit time of acoustic signals between the respective pairs of the plurality of transducers pairs, calculating a plurality of error values (each error value indicative of a cycle skip mode in measuring of the transit time of the acoustic signals), and determining the cycle skip mode using, at least in part, the plurality of error values.

Abstract: Making a transducer having a plastic matching layer which includes providing a transducer housing having a proximal end and a distal end, and bonding a plastic to the distal end of the transducer housing (the plastic fluidly sealing and occluding the distal end). The bonding further includes inserting a cylinder comprising a mold-release chemical into the transducer housing, bonding plastic onto the distal end of the transducer housing, and removing the cylinder when the plastic has hardened.

Abstract: A method and system of determining forthcoming failure of transducers. At least some of the illustrative embodiments are methods comprising creating a first electrical signal representative of acoustic energy propagating between a first pair of transducers of a fluid meter, creating a second electrical signal representative of acoustic energy propagating between a second pair of transducers of the fluid meter (the creating the second electrical signal substantially concurrently with create the first electrical signal), calculating a value indicative of a relationship between a parameter of the first electrical signal a parameter of the second electrical signal, and determining whether performance of the first pair of transducers indicates upcoming failure of at least one transducer of the first pair of transducers, the determining using the value.

Abstract: An embodiment of a piezoelectric assembly for an ultrasonic flow meter comprises a piezoelectric element including a first face and a second face. In addition, the piezoelectric assembly comprises a first electrode engaging the first face. Further, the piezoelectric assembly comprises a second electrode engaging the second face. Still further, the piezoelectric assembly comprises an electrically conductive shim connector attached to the first electrode. Moreover, the piezoelectric assembly comprises a first wire electrically coupled to the shim connector.

Abstract: Acoustic flow meter with dual flow measurements. At least some of the illustrative embodiments are flow meters comprising a spool piece that defines a central passage, a first plurality of transducer pairs mechanically coupled to the spool piece, a second plurality of transducer pairs mechanically coupled to the spool piece, and meter electronics electrically coupled to the first and second plurality of transducer pairs (the meter electronics configured to determine a first value indicative of fluid flow through the central passage, the first value determined using only signals of the first plurality of transducer pairs). The meter electronics further configured to determine a second value indicative of fluid flow through the central passage, the second value determined using only signals of the second plurality of transducer pairs.

Abstract: Coordination of measurement subsystems of a flow meter. At least some of the illustrative embodiments are flow meters comprising a spool piece that defines a central passage, a first plurality of transducer pairs mechanically coupled to the spool piece, a first control electronics electrically coupled to the first plurality of transducer pairs (the first control electronics configured to selectively activate each transducer pair of the first plurality of transducer pairs), a second plurality of transducer pairs mechanically coupled to the spool piece, a second control electronics different than the first control electronics (the second control electronics electrically coupled to the second plurality of transducer pairs, the second control electronics configured to selectively activate each transducer pair of the second plurality of transducer pairs). The first and second control electronics communicatively coupled and configured to coordinate activation of their respective transducer pairs.

Abstract: Coordination of measurement subsystems of a flow meter. At least some of the illustrative embodiments are flow meters comprising a spool piece that defines a central passage, a first plurality of transducer pairs mechanically coupled to the spool piece, a first control electronics electrically coupled to the first plurality of transducer pairs (the first control electronics configured to selectively activate each transducer pair of the first plurality of transducer pairs), a second plurality of transducer pairs mechanically coupled to the spool piece, a second control electronics different than the first control electronics (the second control electronics electrically coupled to the second plurality of transducer pairs, the second control electronics configured to selectively activate each transducer pair of the second plurality of transducer pairs). The first and second control electronics communicatively coupled and configured to coordinate activation of their respective transducer pairs.

Abstract: Detecting liquid in an acoustic flow meter. At least some of the illustrative embodiments are methods comprising flowing a gaseous substance through a central passage of a meter body, sending acoustic signals along respective chordal pathways across the central passage (none of the chordal pathways intersect a lower portion of the central passage where liquid, if present during flow of the gaseous substance, accumulates), calculating a flow velocity of the gaseous substance proximate to each chordal pathway based on transit times of the acoustic signals along the respective chordal pathways, and determining the presence of a liquid accumulated in the lower portion based on the flow velocity proximate to each chordal pathway.

Abstract: Acoustic flow meter with dual flow measurements. At least some of the illustrative embodiments are flow meters comprising a spool piece that defines a central passage, a first plurality of transducer pairs mechanically coupled to the spool piece, a second plurality of transducer pairs mechanically coupled to the spool piece, and meter electronics electrically coupled to the first and second plurality of transducer pairs (the meter electronics configured to determine a first value indicative of fluid flow through the central passage, the first value determined using only signals of the first plurality of transducer pairs). The meter electronics further configured to determine a second value indicative of fluid flow through the central passage, the second value determined using only signals of the second plurality of transducer pairs.

Abstract: A method and system of determining forthcoming failure of transducers. At least some of the illustrative embodiments are methods comprising creating a first electrical signal representative of acoustic energy propagating between a first pair of transducers of a fluid meter, creating a second electrical signal representative of acoustic energy propagating between a second pair of transducers of the fluid meter (the creating the second electrical signal substantially concurrently with create the first electrical signal), calculating a value indicative of a relationship between a parameter of the first electrical signal a parameter of the second electrical signal, and determining whether performance of the first pair of transducers indicates upcoming failure of at least one transducer of the first pair of transducers, the determining using the value.

Abstract: Systems and methods of a transducer having a plastic matching layer. At least some of the illustrative embodiments are methods including providing a transducer housing having a proximal end and a distal end, and bonding a plastic to the distal end of the transducer housing (the plastic fluidly sealing and occluding the distal end). The bonding further includes inserting a cylinder comprising a mold-release chemical into the transducer housing, bonding plastic onto the distal end of the transducer housing, and removing the cylinder when the plastic has hardened.

Abstract: Determining a pattern of arrival time cycle skip in an acoustic flow meter. At least some of the illustrative embodiments are methods comprising transceiving acoustic signals through a fluid flowing in a meter (the transceiving between respective pairs of a plurality of transducer pairs), measuring transit time of acoustic signals between the respective pairs of the plurality of transducers pairs, calculating a plurality of error values (each error value indicative of a cycle skip mode in measuring of the transit time of the acoustic signals), and determining the cycle skip mode using, at least in part, the plurality of error values.

Abstract: Systems and methods of a transducer having a plastic matching layer. At least some of the illustrative embodiments are transducers comprising a housing (having a proximal end, a distal end and an internal volume, the housing configured to couple to a spoolpiece of an ultrasonic meter), a plastic matching layer that has an external surface and an internal surface (the plastic matching layer seals to and occludes the distal end of the housing), and a transducer element abutting the internal surface of the plastic matching layer.

Abstract: Methods and systems for detecting deposit buildup within an ultrasonic flow meter are disclosed. At least some of the illustrative embodiments are ultrasonic flow meters comprising a spool piece configured to couple within a flow of fluid, a first transducer pair mechanically mounted to the spool piece and configured to fluidly couple to the flow of fluids (wherein the first transducer pair comprises an upstream transducer and a downstream transducer in operational relationship to the upstream transducer and defines a first chord there between), and electronics electrically coupled to the first transducer pair. The electronics is configured to detect deposit buildup over an inner surface of the ultrasonic flow meter.

Abstract: Systems and methods of a transducer having a plastic matching layer. At least some of the illustrative embodiments are transducers comprising a housing (having a proximal end, a distal end and an internal volume, the housing configured to couple to a spoolpiece of an ultrasonic meter), a plastic matching layer that has an external surface and an internal surface (the plastic matching layer seals to and occludes the distal end of the housing), and a transducer element abutting the internal surface of the plastic matching layer.