Brine Tank Salt Level Control via Water Line Sensing
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Solution Overview
Problem
Existing methods for monitoring salt levels in brine tanks are unreliable due to variations in tank opacity, interference from dissolved oxygen and foam, maintenance issues with high-intensity lamps, and the risk of breakage and clogging associated with sight glasses and plumb bob indicators.
Innovation Solution
A non-invasive control system that uses a remote location with a memory device, pressure switch sensor, and logic circuit to monitor and control salt levels by supplying water to the brine tank, providing an indication when the salt level falls below a set threshold, and offering a counter to track filling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If external markings are used to monitor salt level, then the monitoring method is simple, but the measurement precision deteriorates due to variations in tank opacities
Solution Approach 1:
A water level sensor is introduced as an intermediary device to indirectly measure salt level. The sensor detects the water line in the brine solution, and since the salt level is always below the water line, this provides an indirect but reliable measurement method that avoids the opacity problems of direct visual marking observation
Solution Approach 2:
The patent replaces the visual/optical marking system with an electronic sensor-based detection system. Instead of relying on optical visibility through the tank, an electronic water level sensor is used to detect the water line position, converting an optical measurement problem into an electronic sensing solution
2Ease of operation
If ultrasonic devices are used to monitor salt level, then the device can operate remotely, but the measurement precision deteriorates due to foam interference from dissolved oxygen
Solution Approach 1:
A water level sensor is introduced as an intermediary to detect the water line position indirectly. This sensor is positioned to measure below the foam layer, using the water line as a reference point that is not affected by foam interference, thereby solving the measurement accuracy problem while maintaining remote operation capability
Solution Approach 2:
The measurement target is extracted from the problematic foam-salt interface and shifted to the water line position below the foam layer. By measuring the water line position instead of directly measuring through or at the foam layer, the system eliminates the interference of dissolved oxygen foam from the measurement process
3Illumination intensity
If high intensity lamps are used to illuminate the brine, then the visibility improves for monitoring, but the device complexity and maintenance requirements worsen due to salt coating on lights
Solution Approach 1:
The patent replaces the mechanical/optical illumination system with an electronic sensing system. Instead of using lights to illuminate the brine for visual monitoring, an electronic water level sensor is used to detect the water line position, eliminating the need for illumination and the associated maintenance of salt-coated lights
Solution Approach 2:
The illumination system is completely removed from the monitoring approach. Rather than trying to improve visibility through lighting, the system extracts the measurement function to an electronic sensor that operates independently of optical visibility requirements
4Measurement precision
If sight glasses are used to monitor salt level, then the measurement precision improves, but the reliability deteriorates due to breakage risk and salt clogging
Solution Approach 1:
A water level sensor is introduced as an intermediary electronic device to detect the water line position. This sensor provides the measurement function without the physical vulnerabilities of sight glasses, eliminating breakage and clogging risks while maintaining the ability to accurately determine salt level through electronic sensing
Solution Approach 2:
The patent replaces the fragile mechanical sight glass system with a robust electronic sensor system. The electronic water level sensor provides the same measurement function (determining liquid level to infer salt level) without the physical vulnerabilities of glass breakage and salt clogging that plague mechanical sight glasses
5Measurement precision
If plumb bob level indicators are used to monitor salt level, then the measurement precision improves, but the reliability worsens when the plumb bob becomes locked in salt during filling
Solution Approach 1:
A water level sensor is introduced as an intermediary electronic device to detect the water line position. This sensor provides continuous electronic monitoring without the mechanical interference problems of plumb bobs, eliminating the risk of the indicator becoming locked in salt during the filling process
Solution Approach 2:
The patent replaces the mechanical plumb bob indicator system with an electronic sensor system. The electronic water level sensor provides the same measurement function (determining liquid level to infer salt level) without the mechanical vulnerabilities of plumb bobs becoming embedded in salt or failing to reset
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
The system effectively monitors and maintains optimal salt levels in brine tanks, reducing maintenance needs and personnel exposure to harsh environments while ensuring accurate and reliable salt level detection.
Implementation Method 1
The sensor comprises a pressure switch sensing pressure at the water inlet
Data Source
AI summary
A control system monitors salt level in a brine tank having a water inlet. The control system comprises a memory device storing an amount representing actual salt level in the brine tank. A sensor determines water level in the brine tank. A control valve is operatively connected between a water supply and the water inlet for controllably supplying water to the brine tank. A logic circuit is operatively connected to the memory device, the sensor and the control valve for determining salt level in the brine tank. The logic circuit periodically operates the control valve responsive to sensed water levels to fill the brine tank with water, updates the stored actual salt level in the memory device responsive to water supplied to the brine tank, and provides an indication when actual salt level in the brine tank falls below a select salt level.