Fluid top-off detection and control system
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Solution Overview
Problem
Existing control systems for fluid heating sources, such as deep fryers, face challenges in accurately detecting fluid levels due to debris and viscosity issues, leading to inefficient operation and unsanitary conditions with traditional sensors like float-based and capillary sensors.
Innovation Solution
A capacitive sensor system that determines fluid levels by measuring capacitance between the sensor and the container walls, allowing for reliable and sanitary fluid management across a wide range of viscosities, from partially solid to low viscosity, using a capacitive sensor probe and associated electronics interfaced with a microcontroller for automatic fluid supplementation or removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If float-based level sensors are used to detect fluid level, then the sensor can provide continuous level indication, but debris in the fluid causes the float to become stuck and fail to ride freely along the shaft
Solution Approach 1:
The patent replaces the mechanical float-based level sensing system with a capacitive sensing system. The capacitive sensor detects fluid level through electrical field interaction with the fluid, eliminating mechanical components that can become stuck. This substitution resolves the contradiction by maintaining measurement precision while significantly improving reliability in debris-containing environments.
Solution Approach 2:
The capacitive sensor acts as an intermediary that detects fluid level without direct physical contact with the fluid. By using electrical field interaction through the container wall, the sensor avoids direct exposure to debris while still accurately measuring fluid level, thus resolving the contradiction between measurement accuracy and operational reliability.
2Measurement precision
If capillary sensors are used to detect fluid level, then the sensor can determine level based on fluid location in the tube, but differences in fluid viscosity prevent capillary action from working effectively
Solution Approach 1:
The patent replaces capillary action-based level detection with capacitive sensing. The capacitive sensor measures fluid level through electrical field interaction, which is independent of fluid viscosity. This resolves the contradiction by maintaining measurement precision while achieving universal adaptability across fluids of all viscosities, including partially solid phases.
Solution Approach 2:
The patent changes the detection parameter from capillary rise (which depends on viscosity) to electrical capacitance (which is independent of viscosity). By measuring the capacitive effect of the fluid on the sensor, the system achieves consistent level detection across a wide range of fluid viscosities, resolving the contradiction between measurement accuracy and adaptability.
3Measurement precision
If capillary sensors are used in fluid detection, then the sensor can provide level sensing, but fluid retention in the capillary creates unsanitary conditions that are difficult to clean
Solution Approach 1:
The capacitive sensor serves as an intermediary that detects fluid level through the container wall without direct fluid contact. This eliminates the capillary structure that retains fluid, allowing easy cleaning and maintenance while preserving level detection accuracy. The sensor interacts with the fluid's electrical properties through the wall barrier, maintaining measurement capability without sanitation issues.
Solution Approach 2:
The patent extracts the fluid retention problem by eliminating the capillary structure entirely. The capacitive sensor system detects fluid level without requiring any fluid-filled passages or capillary tubes, thus removing the source of sanitation problems while maintaining measurement precision through electrical field interaction.
4Measurement precision
If traditional sensors are used in cooking environments, then the sensors can detect fluid level, but air pockets or bubbles retained within the sensor cause temperature changes that lead to sensor failure
Solution Approach 1:
The capacitive sensor acts as an intermediary that detects fluid level through the container wall, avoiding direct exposure to extreme temperature fluctuations and air pockets. This indirect detection method protects the sensor from thermal shock while maintaining measurement accuracy through capacitive coupling with the fluid.
Solution Approach 2:
The patent replaces traditional direct-contact sensors with a capacitive sensing system that measures fluid level through electrical field interaction. This substitution eliminates the problem of air pockets causing thermal expansion and sensor failure, as the capacitive sensor is not directly exposed to temperature changes while maintaining measurement precision.
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 capacitive sensor system provides accurate and continuous fluid level monitoring, preventing insufficient fluid conditions and maintaining sanitary conditions by automatically adjusting fluid levels, enhancing operational reliability and safety in cooking environments.
Implementation Method 1
A capacitive sensor system that determines fluid levels by measuring capacitance between the sensor and the container walls
Implementation Method 2
measuring capacitance between the sensor and the container walls
Data Source
AI summary
A capacitive sensor and control system is configured to detect the presence (or absence) of fluid within a container. Configured in a vat of a deep fryer, the sensor determines when a level of liquid within the vat is at or above the level of the sensor. The sensor is in communication with the control system and the sensor sends a signal to the control system representative of the presence or absence of liquid within the vat and at the level of the sensor. The controller receives the signal from the sensor, and allows operation of a fluid management system and its associated plumbing to maintain an appropriate level of liquid in the vat.