Bespoke calibration rigs unlock ultra-low flow ultrasonic measurement

Titan Enterprises has published a technical paper detailing how its team tackled calibration challenges in pioneering ultrasonic flowmeter development for ultra-low flow applications.

Recognising that no off-the-shelf system could meet the precise requirements of its latest research, Titan designed bespoke calibration rigs in-house to support next-generation ultra-low flow and clamp-on ultrasonic flowmeters. Existing production rigs - three certified piston provers operating across 2 ml/min to 200 l/min with ±0.05% uncertainty - were heavily used and insufficient for the novel testing parameters required for advanced R&D.

The new ultra-low flow calibration rig is central to two major innovations. First, an ultrasonic flowmeter capable of measuring flows as low as 0.2 ml/min, roughly ten times lower than Titan’s Atrato® meter, offering a competitive alternative to thermal devices. Second, a clamp-on ultrasonic flowmeter designed for disposable medical tubing, targeting applications such as dialysis and bolus drug delivery where accuracy, sterility, and cost-effectiveness are critical.

To achieve these capabilities, Titan developed a state-of-the-art miniature piston prover system featuring dual synchronised stepping motors with rotational encoders for precise tracking. The system incorporates computer-controlled flow ranges, bolus simulation, and extensive data output for in-depth performance analysis. Complex mechanical and hydraulic factors - such as valve synchronisation, linear motion stability, drive stiffness, tubing compliance, and temperature effects - were carefully addressed, alongside safety features including end-of-stroke detection.

“By building our own calibration infrastructure, we are unlocking new performance frontiers for both industrial and medical flow applications,” said Neil Hannay, Senior R&D Engineer.

Titan’s in-house calibration and testing capability accelerates the path from prototype to verified product. Proprietary software enables rapid evaluation of multiple real-world scenarios, ensuring customer processes are optimised. The design principles established in this project also pave the way for future developments, including novel fluid test units and fully temperature-controlled systems, supporting cutting-edge solutions for universal applications and OEM-specific needs.

The full technical paper is available via Titan Enterprises’ website. 

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