Adjustable Bracket Mounting Assembly for Condensate Level Sensors
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Solution Overview
Problem
Existing mounting systems for liquid level sensors in HVAC systems are complex and limited to specific drain pan geometries, making it difficult to achieve proper positioning and accessibility for sensor installation and servicing.
Innovation Solution
A mounting assembly with a stationary bracket coupled to the drain pan and an adjustable bracket that supports the liquid level sensor, allowing for independent linear and angular adjustments, along with visual indicators for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed mounting system is used for liquid level sensors, then the mounting structure is simple, but it is limited to specific drain pan geometries and cannot accommodate various orientations and elevations
Solution Approach 1:
The mounting system employs adjustable brackets that can be positioned at different locations and angles, transforming a fixed rigid structure into a dynamic adaptable one. The brackets can be adjusted to accommodate various drain pan geometries and sensor orientations while maintaining structural integrity through secure fastening mechanisms.
Solution Approach 2:
The mounting system is designed with universal brackets and fasteners that can be configured for different drain pan types and sensor models. The same basic mounting structure serves multiple functions: providing structural support, enabling angular adjustment, allowing positional variation, and securing the sensor firmly in place.
2Adaptability or versatility
If a complex adjustable mounting system is used to accommodate various drain pan geometries, then adaptability is improved, but installation and servicing become more difficult
Solution Approach 1:
The mounting system is divided into separate modular components: mounting brackets, fasteners, and sensor holders. Each component can be independently adjusted and positioned, allowing installers to configure the system for different geometries without dealing with a monolithic complex structure. This segmentation simplifies both installation and future servicing.
Solution Approach 2:
The adjustable brackets incorporate movable elements that can be easily repositioned along marked positions before being secured. This dynamic capability allows for quick adjustment during installation and easy reconfiguration during servicing, maintaining ease of operation while achieving high adaptability to various orientations and elevations.
3Measurement precision
If the liquid level sensor is not properly positioned, then the mounting system is simpler, but detection accuracy of condensate levels deteriorates
Solution Approach 1:
The system replaces complex mechanical positioning calculations with visual angle markers and pre-configured bracket positions. Instead of requiring precise mechanical measurements and adjustments, the brackets come with marked positions that guide installers to the correct angular and positional settings for accurate sensor detection, simplifying the positioning mechanism while ensuring measurement precision.
Data Source
AI summary
In an embodiment of the present disclosure, a condensate level switch mounting assembly includes a condensate level switch having a mounting frame, a first bracket configured to fixedly attach to a condensate drain pan, and a second bracket having a mounting plate configured to engage with the mounting frame of the condensate level switch to secure the condensate level switch to the second bracket. The condensate level switch mounting assembly further includes a fastener assembly configured to couple the second bracket to the first bracket such that an angular position of the second bracket is adjustable relative to the first bracket.