Capacitive Fluid Level Sensor Field Configuration Without Teach Wire
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Solution Overview
Problem
Capacitive-based fluid level sensors require additional cost, power consumption, and design complexity for field configuration due to the need for a 'teach function' wire, which is not ideal for non-contact mounting.
Innovation Solution
Incorporating a capacitive touch sensor or push button mechanism to enable field configuration without a 'teach function' wire, allowing users to reprogram the sensor by adjusting fluid levels and touching a conductive surface in a predetermined sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a teach function wire is included in the sensor's wiring bundle for field configuration, then the sensor can be configured to accommodate changing physical conditions, but additional cost, power consumption, and design complexity are required
Solution Approach 1:
The patent combines the touch sensor plate and fluid level sensor plate into a single sensor assembly, eliminating the need for a separate teach function wire. The touch sensor plate serves dual purposes: it acts as both the sensing element for fluid level detection and the interface for field configuration through capacitive touch input.
Solution Approach 2:
The sensor performs self-configuration through capacitive touch input from a user's finger, eliminating the need for external configuration equipment or additional wiring. The existing sensor plates and control unit are utilized to detect touch input and reprogram the sensor thresholds, making the system self-sufficient for field configuration.
2Adaptability or versatility
If a teach function wire is included in the sensor's wiring bundle for field configuration, then the sensor can be configured to accommodate changing physical conditions, but additional power consumption is required
Solution Approach 1:
The sensor utilizes the user's finger as the configuration input device, eliminating the need for external power sources or additional powered components for field configuration. The capacitive touch sensing leverages the natural electrical properties of the human body, requiring no additional power consumption beyond what is already used for normal sensor operation.
Solution Approach 2:
The sensor plates serve multiple functions: they detect fluid levels during normal operation and detect capacitive touch input during configuration mode. This multi-functionality eliminates the need for separate dedicated configuration wiring that would require additional power.
3Adaptability or versatility
If a teach function wire is included in the sensor's wiring bundle for field configuration, then the sensor can be configured to accommodate changing physical conditions, but additional cost is required
Solution Approach 1:
The patent merges the configuration interface functionality into the existing sensor plates, eliminating the need to manufacture and install separate teach function wires or additional configuration components. This reduces both material costs and assembly complexity.
Solution Approach 2:
The patent extracts the configuration capability from requiring external hardware (teach wire) and implements it through software control of the existing sensor plates. This eliminates the need for additional physical components that would increase manufacturing cost.
4Adaptability or versatility
If a teach function wire is included in the sensor's wiring bundle for field configuration, then the sensor can be configured to accommodate changing physical conditions, but additional design complexity is required
Solution Approach 1:
The patent combines the configuration interface and sensing functions into a single integrated system using the existing sensor plates and control unit, eliminating the need for separate teach function wire design and reducing overall system 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
Enables convenient and cost-effective field configuration of fluid level sensors by eliminating the need for additional wiring and power, simplifying the design and reducing operational complexity.
Implementation Method 1
The touch feature is a capacitive touch sensor plate
Implementation Method 2
Capacitive based sensors typically monitor an electric field generated by a fill level sensor and corresponding reference electrode. The fill level of fluid in a container affects this electric field due to a difference between a dielectric constant of the fluid in the container and a dielectric constant of the gas in the container
Implementation Method 3
The fill level of fluid in a container affects this electric field due to a difference between a dielectric constant of the fluid in the container and a dielectric constant of the gas in the container
Data Source
AI summary
Systems, apparatuses, and methods provide for a fluid level sensor including a fluid level sensor plate, a touch sensor plate, and a control unit. The fluid level sensor plate comprises a plate of conductive material. The touch sensor plate comprises a plate of conductive material. The control unit is coupled to the fluid level sensor plate and the touch sensor plate. The control unit is configured to determine fluid presence based on fluid level data from the fluid level sensor plate and determine touch input based on touch data from the touch sensor plate.