Automatic fill control technique
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Solution Overview
Problem
Existing pump control techniques maintain pressure in lines, leading to unnecessary operation when lines burst, causing the pump to deplete the supply if not shut off properly when not in use.
Innovation Solution
A signal processor or microcontroller-based system that senses low liquid levels in a reservoir and automatically refills it using level sensing technology, eliminating the need for pressure relief and incorporating user-calibrated refill procedures to prevent overfilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure is maintained in the lines to shut off the pump when not in use, then the pump can be kept shutdown, but the pump will pump until supply is depleted if the lines burst
Solution Approach 1:
The patent replaces the mechanical pressure-based shutdown system with an electronic control system using a microcontroller and level sensors. The microcontroller monitors reservoir levels and controls pump operation electronically, eliminating the need to maintain pressure in lines for shutdown control. This substitution allows the pump to be reliably shut off without the harmful effect of uncontrolled pumping when lines burst.
Solution Approach 2:
The patent implements a feedback mechanism where level sensors continuously monitor the reservoir liquid level and provide signals to the microcontroller. The microcontroller adjusts pump operation based on this feedback, turning the pump off when the reservoir is full and on when liquid is needed. This closed-loop control ensures reliable pump shutdown without maintaining line pressure, preventing uncontrolled pumping in case of line bursts.
2Extent of automation
If level sensing technology is used to determine when to refill, then automatic refill control is achieved, but user calibration is required to determine correct refill timing
Solution Approach 1:
The patent implements a self-calibration feature where the system automatically determines the correct refill timing by monitoring the reservoir level during a calibration period. The microcontroller tracks when the reservoir reaches full and empty levels autonomously, eliminating the need for manual user calibration. This maintains automatic refill control while significantly reducing device complexity and user burden.
3Device complexity
If the pump operates without automated control, then simpler hardware is needed, but the pump cannot shut off automatically when the reservoir is full
Solution Approach 1:
The patent replaces complex mechanical automatic shutdown mechanisms with a simpler electronic control system. The microcontroller and level sensors provide reliable automatic shutdown when the reservoir is full, while requiring less complex mechanical components than traditional pressure-based systems. This electronic substitution achieves both automatic reliability and reduced overall device complexity.
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
Effectively shuts off the pump when not in use, ensures efficient refilling of the reservoir without pressure maintenance, and prevents overfilling through user-calibrated timeout features, enhancing safety and operational efficiency.
Implementation Method 1
The low level sensor is configured using capacitive-based sensing that is not in contact with the liquid in the appliance reservoir
Data Source
AI summary
A pump includes a signal processor that receives signaling containing information about a low level of a liquid sensed in an appliance reservoir to be supplied to an appliance that uses the liquid to dispense a flavored beverage, and also about when the appliance reservoir is refilled based upon an indication that forms part of an appliance reservoir refill level calibration procedure programmed by an appliance user; and determines corresponding signaling containing information about automatically refilling the liquid in the appliance reservoir, based upon the signaling received.