Compressor Lubricant Level Sensing Using Dual Temperature Sensors
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Solution Overview
Problem
Existing compressor systems lack an efficient method to determine the lubricant level in the lubricant sump, which can lead to inadequate lubrication, causing operational issues and potential damage.
Innovation Solution
Incorporating a control module that communicates with first and second temperature sensors and a pressure sensor to determine the lubricant level by measuring temperature differences and pressures within the compressor, using standard deviations and ratios to assess the liquid level accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors and pressure sensors are used to determine lubricant level, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces direct mechanical level sensing with a thermal-conductive field-based detection system. Temperature sensors measure thermal conductivity differences caused by varying lubricant levels, substituting mechanical contact with field-based measurement to improve precision while managing complexity.
Solution Approach 2:
The patent introduces thermal conductivity as an intermediary parameter between lubricant level and temperature measurement. The control module uses this intermediary to infer lubricant level indirectly through temperature differential measurements, resolving the contradiction between direct measurement precision and system complexity.
2Reliability
If multiple sensors are integrated into the compressor, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges multiple sensing functions (temperature measurement and pressure sensing) into a single integrated control module system. This consolidation improves reliability through multi-parameter monitoring while facilitating manufacture by reducing the number of separate components that need assembly.
Solution Approach 2:
The control module serves multiple functions: it processes data from both temperature sensors and pressure sensors, determines lubricant levels, and monitors compressor operation. This multi-functionality improves reliability through comprehensive monitoring while simplifying manufacture by using a single universal control unit rather than separate dedicated devices.
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 system effectively determines the lubricant level, preventing lubricant-related operational issues and ensuring the compressor operates within optimal conditions, thereby extending its lifespan and maintaining efficient performance.
Implementation Method 1
The first temperature sensor is at least partially disposed within the shell at a first position. The second temperature sensor is at least partially disposed within the shell at a second position that is vertically higher than the first position.
Implementation Method 2
the compressor includes a pressure sensor disposed at least partially within the shell. The control module may determine whether the liquid level is below the predetermined level based on whether data from the pressure sensor indicates a presence of liquid working fluid in the shell.
Implementation Method 3
the compressor includes a heating element configured to heat liquid within said lubricant sump.
Data Source
AI summary
A compressor may include a shell, a compression mechanism, first and second temperature sensors, and a control module. The shell may define a lubricant sump. The compression mechanism may be disposed within the shell and may be operable to compress a working fluid. The first temperature sensor may be at least partially disposed within the shell at a first position. The second temperature sensor may be at least partially disposed within the shell at a second position that is vertically higher than the first position. The control module may be in communication with the first and second temperature sensors and the pressure sensor and may determine whether a liquid level in the lubricant sump is below a predetermined level based on data received from the first and second temperature sensors.