Compressor Lubricant Sump Level Detection Using Dual Temperature Sensors
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Solution Overview
Problem
Existing compressor systems lack an efficient method to determine the lubricant level accurately, which can lead to inadequate lubrication, causing operational issues and potential damage.
Innovation Solution
The compressor system incorporates first and second temperature sensors and a control module that determine the lubricant level by measuring temperature differences and using a pressure sensor to verify the presence of liquid, with optional heating elements to maintain lubricant temperature and slosh guards to protect sensors from liquid exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are used to determine lubricant level, then measurement capability is provided, but device complexity increases
Solution Approach 1:
The patent replaces direct mechanical level sensing with thermal field-based measurement. Temperature sensors measure the thermal state of the lubricant, and the control module infers liquid level from temperature differences and thermal conductivity variations, eliminating the need for direct mechanical contact with the lubricant.
Solution Approach 2:
The patent introduces temperature as an intermediary parameter to indirectly measure lubricant level. Instead of directly detecting liquid level, the system uses temperature sensors to detect thermal properties that correlate with lubricant presence and level, with the control module establishing the relationship between temperature data and liquid level.
2Loss of information
If multiple sensors are added to the shell, then measurement capability improves, but device complexity increases
Solution Approach 1:
The patent divides the monitoring function into multiple temperature sensors positioned at different locations within the shell. Each sensor measures local thermal conditions, and the control module integrates these segmented measurements to determine overall lubricant level, providing spatial resolution of the thermal field.
Solution Approach 2:
The temperature sensors serve multiple functions: they monitor lubricant level, detect lubricant temperature, and provide data for control decisions. The same sensor infrastructure supports both measurement and control functions, reducing the need for separate dedicated components.
3Reliability
If heating element is added to maintain lubricant temperature, then operational reliability improves, but device complexity and energy consumption increase
Solution Approach 1:
The heating element provides preliminary thermal conditioning of the lubricant, particularly during startup or idle periods. By pre-heating the lubricant before the compressor begins operation, the system ensures proper lubrication conditions are established in advance, preventing wear during critical startup phases.
Solution Approach 2:
The heating element operation is controlled by feedback from temperature sensors. The control module continuously monitors lubricant temperature and activates the heating element only when temperature falls below a threshold, creating a closed-loop control system that maintains temperature within acceptable ranges while minimizing energy consumption.
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
This solution ensures accurate detection of lubricant levels, preventing lubricant-related operational issues and providing timely alerts or shutdowns to maintain compressor efficiency and extend its lifespan.
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 determines 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
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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.