Combined Temperature and Low Water Sensor for Hydronic Furnaces
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Solution Overview
Problem
Hydronic heating systems face issues where malfunctioning water temperature sensors can lead to incorrect furnace control, potentially causing overheating and damage due to undetected low water conditions, as they fail to simultaneously monitor water presence and temperature effectively.
Innovation Solution
A compact sensor that detects both the temperature of a conductive liquid and its presence by using a non-conductive plastic body with a conductive detection tip and thermistors, communicating through the furnace wall to provide accurate water level and temperature data to the control system, ensuring proper furnace operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate temperature sensor and water level sensor are used, then each sensor can be optimized for its specific function, but the device complexity increases and reliability decreases due to multiple failure points
Solution Approach 1:
The patent combines a temperature sensor and a water level sensor into a single integrated sensor assembly. The temperature sensor (thermistor) and water level sensor (electrode) are housed together in one non-conductive body with a single sealable penetration through the furnace wall, eliminating the need for multiple separate sensors and their associated mounting requirements.
Solution Approach 2:
The single sensor assembly performs multiple functions: it simultaneously measures water temperature via the thermistor and detects water presence via the electrode. This multi-functional design allows one sensor unit to replace what would traditionally require separate dedicated sensors for each measurement type.
2Device complexity
If a single sensor performs both temperature and water level detection, then device complexity is reduced and reliability is improved, but measurement precision may be compromised due to integrated design constraints
Solution Approach 1:
Within the unified sensor body, the temperature sensing function (thermistor) and water level sensing function (electrode) are physically segmented and electrically isolated from each other. Each sensing element maintains its own dedicated signal path and measurement circuitry, allowing both to operate independently with full precision despite being housed in the same assembly.
Solution Approach 2:
The non-conductive body acts as an intermediary structure that houses both sensing elements while electrically isolating them. The body provides mechanical support and environmental protection while preventing electrical interference between the conductive electrode and the temperature sensor, ensuring both measurements remain accurate.
3Measurement precision
If multiple sensors are installed to monitor both temperature and water level, then measurement precision is maintained, but the ease of operation decreases due to multiple installation and maintenance points
Solution Approach 1:
The patent combines a temperature sensor and a water level sensor into a single integrated sensor assembly. The temperature sensor (thermistor) and water level sensor (electrode) are housed together in one non-conductive body with a single sealable penetration through the furnace wall, eliminating the need for multiple separate sensors and their associated mounting requirements.
4Ease of manufacture
If separate sensors are used for temperature and water level detection, then each sensor can be optimized independently, but loss of time increases due to multiple maintenance and replacement operations
Solution Approach 1:
The patent combines a temperature sensor and a water level sensor into a single integrated sensor assembly. The temperature sensor (thermistor) and water level sensor (electrode) are housed together in one non-conductive body with a single sealable penetration through the furnace wall, eliminating the need for multiple separate sensors and their associated mounting requirements.
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 sensor effectively prevents overheating and damage by accurately detecting water presence and temperature, allowing the control system to take appropriate actions, such as shutting down the furnace in low-water conditions, thus ensuring safe and efficient operation.
Implementation Method 1
A compact sensor that detects both the temperature of a conductive liquid and its presence by using a non-conductive plastic body with a conductive detection tip and thermistors
Implementation Method 2
An electrode is attached to the first portion of the body and is configured for electrical communication with the water on the inside of the wall
Data Source
AI summary
A combination temperature and low water sensor includes a body configured to penetrate the wall of a hydronic furnace. A detection tip is attached to the body and extends into the furnace when the temperature sensor penetrates the wall. The detection tip is electrically conductive and defines a tip interior volume. A temperature sensor is disposed within the interior volume of the detection tip. Both the detection tip and the temperature sensor are configured for electrical connection to a furnace control system.