Capacitive Liquid Level Sensor for Battery Electrolyte Monitoring
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Solution Overview
Problem
Conventional liquid electrolyte battery monitoring systems lack accurate water level measurement capabilities, leading to frequent refilling needs without user alerts, as existing indicators can only determine contact with electrolyte and not the actual level within the battery cell.
Innovation Solution
A capacitive liquid level sensor with a probe featuring an electrode array and reference electrode, mounted on a dielectric substrate, which measures capacitance changes to determine the liquid level and alert users or control the refilling process, including real-time monitoring and wireless communication of data for remote analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional conductive material indicators are used to detect electrolyte contact, then the device complexity is low, but the measurement precision of liquid level is insufficient
Solution Approach 1:
The probe is divided into multiple discrete capacitive sensing elements arranged vertically along its length. Each sensing element independently measures the liquid level at its specific position, allowing the system to detect multiple liquid level thresholds simultaneously. This segmentation approach enables precise liquid level measurement while maintaining relatively simple individual sensor structures.
Solution Approach 2:
The invention replaces conventional conductive material indicators with capacitive sensing elements. This substitution transitions from a simple conductive contact mechanism to a capacitive measurement system that can detect liquid level through dielectric changes, significantly improving measurement precision while keeping the overall device structure manageable.
2Productivity
If frequent refilling is performed without accurate monitoring, then the loss of time for battery operation is reduced, but the loss of substance through excessive refilling increases
Solution Approach 1:
The capacitive liquid level sensor provides real-time feedback on the actual liquid level within the battery cell. This feedback mechanism enables the watering system to accurately determine when refilling is needed, preventing both premature refilling (which wastes electrolyte) and delayed refilling (which reduces operational time). The system can trigger refilling operations based on precise level detection.
Solution Approach 2:
The sensor detects liquid level conditions in advance before critical depletion occurs. By providing early warning of low liquid levels, the system enables proactive refilling planning, ensuring continuous battery operation while avoiding electrolyte loss from excessive or unnecessary refilling operations.
3Ease of operation
If conventional single point watering systems are used, then the ease of operation for refilling is improved, but the reliability of liquid level monitoring is insufficient
Solution Approach 1:
The probe incorporates multiple capacitive sensing elements at different vertical positions, each providing independent liquid level detection. This segmented approach allows the system to reliably determine the actual liquid level and distinguish between different filling stages, significantly improving monitoring reliability while maintaining the simplicity of single-point watering operation.
Solution Approach 2:
The capacitive sensor array serves multiple functions: it detects liquid level presence, determines precise liquid level height, and can identify different liquid types based on dielectric properties. This multi-functionality enhances reliability without complicating the basic refilling operation, as the system automatically processes the detailed measurements.
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
Provides accurate, real-time liquid level and temperature monitoring, enabling timely refilling and maintaining optimal battery conditions, with the ability to control the flow of liquid based on detected levels, thereby improving battery operation and longevity.
Implementation Method 1
the capacitive sensor provides an output that varies as the liquid level increases in relation to the probe
Implementation Method 2
detecting variations in the dielectric of a substance being sensed
Data Source
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AI summary
A liquid level sensor for a liquid electrolyte battery is provided. The liquid level sensor includes a probe having a reference electrode and an electrode array. The electrode array includes a plurality of electrodes that are serially disposed in a lengthwise direction of the probe. The reference electrode is capacitively coupled to each electrode within the electrode array, such that the probe provides a capacitance that varies when the probe is immersed in a liquid level that varies in relation to the probe. The liquid level sensor can alert a user of the need to refill the battery or alert a user of the need to refill the battery in the near future. The liquid level sensor can include a series of LEDs that selectively illuminate to indicate each such condition to the user.