Capacitive Priming Sensor Geometry for Debris-Laden Pump Chambers
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Solution Overview
Problem
Existing vacuum primed pumps used in environments with debris and changing conditions suffer from false prime detections due to debris coating or wrapping around traditional sensors, leading to maintenance issues and improper operation.
Innovation Solution
A pumping system with a cylindrical sensor having a spherical cap sensing dome and adjustable settings, capable of detecting fluid presence and adjusting sensitivity based on fluid characteristics, including debris presence, using capacitive technology and an embedded algorithm to prevent false priming and optimize operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensors are extended into the priming chamber to detect fluid presence, then the pump can be monitored for proper priming, but debris in the fluid will coat or wrap around the sensors causing false prime detections
Solution Approach 1:
The sensing element is extracted from direct contact with the fluid by placing it in a protected housing above the fluid level. The housing allows electromagnetic sensing through its walls without requiring the sensor to be physically immersed in the debris-filled fluid, thereby eliminating debris coating while maintaining detection capability.
Solution Approach 2:
The housing acts as an intermediary between the sensor and the fluid. It transmits electromagnetic signals to and from the sensing element while physically isolating the sensor from direct contact with debris, enabling indirect detection of fluid presence through the housing walls.
2Measurement precision
If sensors are positioned to detect fluid presence accurately, then pump operation can be controlled properly, but the sensors become more susceptible to false readings under changing fluid conditions
Solution Approach 1:
The system dynamically adjusts sensor sensitivity and detection parameters based on detected fluid characteristics. The controller modifies sensing thresholds and parameters in response to changing fluid conditions, maintaining accurate detection across varying operational environments.
Solution Approach 2:
The system continuously monitors fluid presence and characteristics, using this feedback to adjust sensor sensitivity and operational parameters. This closed-loop control ensures the sensor remains calibrated for current conditions, preventing false readings when fluid composition changes.
3Ease of operation
If the pump is positioned above the liquid level for vacuum priming, then the pump can operate with reduced priming requirements, but the pump cannot operate properly without a head of fluid extending into the pump
Solution Approach 1:
The system uses the pump's own positioning and the sensor-based detection to automatically ensure proper priming before operation. The controller activates the primer pump only when sensors confirm sufficient fluid head is present, making the system self-verifying and eliminating the need for manual priming verification.
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
Reduces false prime detections and maintenance frequency by accurately sensing fluid levels, even in environments with debris, through adjustable sensitivity and diagnostics, ensuring reliable pump operation.
Implementation Method 1
A sensor has a cylindrical shaft extending into the priming chamber with a sensing dome on an end of the cylindrical shaft at the selected depth
Data Source
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AI summary
A pumping system including a pumping chamber with a fluid sensor having a cylindrical shaft extending into the priming chamber. The sensor has a sensing dome on an end of a cylindrical shaft extending into the priming chamber, with the dome having a vertical base having a diameter less than the cylindrical shaft diameter. The sensor signals a controller whether liquid is present based on an algorithm with settings for dampening of the electromagnetic field, conductance of the electric field, and/or permittivity of the magnetic field using settings which correlate to the fluid environment. The controller controls operation of the pump and primer based on the sensor signal.