Capacitive Liquid Level Encoder with Dual Fine-Coarse Resolution
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Solution Overview
Problem
Existing liquid level transmitter systems, such as those using optical and magnetic encoders, face issues like susceptibility to contamination, LED failure, and resolution degradation due to misalignment, which affect accuracy and reliability.
Innovation Solution
A dual electronic encoder system with a mechanical assembly in a storage tank, comprising a first encoder for fine level measurements and a second encoder for coarse level measurements, along with a processor to control and process the data, providing a reliable and real-time liquid level monitoring and transmission system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical encoders are used for liquid level measurement, then measurement precision can be achieved, but the system becomes susceptible to dust and contaminates and LED failure
Solution Approach 1:
The patent replaces optical encoders with capacitive encoders, substituting an optical measurement system with a capacitive electrical system. This eliminates susceptibility to dust and contaminates that plague optical systems, while maintaining measurement precision through capacitive sensing of the encoder disk position.
Solution Approach 2:
The patent uses capacitive encoders that are more robust and less prone to failure compared to optical encoders with LEDs. The capacitive sensing mechanism has no fragile optical components that can fail, providing long-term reliability without requiring replacement.
2Reliability
If magnetic encoders are used for liquid level measurement, then the system can operate reliably, but resolution degradation occurs due to misalignment between magnets and sensors
Solution Approach 1:
The patent replaces magnetic encoders with capacitive encoders, substituting a magnetic field-based system with a capacitive electrical system. This eliminates the misalignment issues between magnets and sensors that cause resolution degradation, as capacitive sensing does not require precise magnetic alignment.
Solution Approach 2:
The patent changes the physical principle from magnetic field interaction to capacitive field interaction. This parameter change in the sensing mechanism eliminates dependence on precise magnetic alignment while maintaining reliable operation and high measurement precision.
3Device complexity
If a single encoder is used for liquid level measurement, then device complexity is reduced, but measurement precision across the full range is compromised
Solution Approach 1:
The patent divides the measurement range into two segments: a first encoder handling coarse measurements (full range) and a second encoder handling fine measurements (local precision). This segmentation allows each encoder to be optimized for its specific function, maintaining high precision across the entire measurement range while managing system complexity.
Solution Approach 2:
The patent adds a second dimensional layer of measurement by introducing a fine encoder that provides high-resolution data within the range covered by the coarse encoder. This creates a two-dimensional measurement space (coarse + fine) that achieves superior overall precision without proportionally increasing 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
The system achieves high accuracy and reliability in liquid level determination, minimizing errors and maintaining performance across various environmental conditions, with the capacitive encoders offering improved resolution and alignment independence.
Implementation Method 1
capacitive, absolute encoders
Data Source
AI summary
A liquid level monitoring and transmission system includes a mechanical assembly in communication with the liquid in a container and a dual electronic encoder assembly in communication with the mechanical assembly for determining liquid level. The dual electronic encoder assembly includes a first encoder for encoding data indicative of fine level measurements and a second encoder for encoding data indicative of coarse level measurements. The system further includes at least one processor for controlling operation of the first and second encoders and for processing encoded data therefrom and a power control system.