Method for collecting condensate inside an apparatus, apparatus equipped with a condensate collection system and motor-pump assembly intended for a condensate collection system
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Solution Overview
Problem
Existing condensate collection systems in appliances like tumble dryers and air conditioners rely on float-type level sensors, which increase costs and are prone to jamming, and have inefficient energy consumption due to prolonged pump activation times even when condensate is minimal.
Innovation Solution
A method that uses a condensate discharge pump with a local control board to detect low load conditions by measuring actuation time, eliminating the need for float sensors and optimizing energy use by interrupting pump operation when the bottom tank is empty, and signaling full conditions based on prolonged actuation times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a float-type level sensor is used to detect full condition, then the collection system can signal when full, but the sensor increases manufacturing costs and is prone to jamming
Solution Approach 1:
The patent removes the float-type level sensor from the system entirely. Instead, it uses the condensate discharge pump's operational characteristics (current consumption, actuation time) to detect when the collection tank is full. This extraction of the problematic sensor resolves the contradiction by eliminating the reliability issues of float sensors while reducing device complexity.
Solution Approach 2:
The patent replaces the mechanical float sensor system with an electronic control system that monitors the pump's electrical parameters. The control board measures current consumption and actuation time to infer tank fullness, substituting mechanical detection with electrical measurement to achieve both reliability and simplicity.
2Productivity
If the condensate discharge pump is activated at regular intervals for a predetermined time, then the bottom tank can be emptied, but energy consumption increases when condensate is minimal
Solution Approach 1:
The patent makes the pump's operation dynamic rather than static. Instead of fixed predetermined activation times, the pump operates based on real-time detection of actual condensate levels through current consumption monitoring. The pump activates only when needed and stops when the tank is empty, optimizing both productivity and energy consumption.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the pump's current consumption during operation. When current drops below a threshold indicating empty tank conditions, the system stops pump activation. This feedback mechanism ensures the pump runs only when condensate is present, eliminating wasteful energy consumption while maintaining effective emptying productivity.
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 approach reduces production and maintenance costs, enhances reliability, and optimizes energy consumption by avoiding unnecessary pump operation, while eliminating the need for float sensors and ensuring accurate full condition detection without sensor malfunctions.
Implementation Method 1
a condensate discharge pump intended to displace liquid from the bottom collection tank to the top collection tank
Implementation Method 2
an overflow system which causes displacement of the liquid contained in the top collection tank and exceeding an overflow level into the bottom collection tank
Data Source
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AI summary
Method for collecting the condensate inside an apparatus (500), said method comprising the following steps: - providing a condensate collection system comprising: a bottom collection tank and a top collection tank; a condensate discharge pump intended to displace liquid from the bottom collection tank to the top collection tank; and an overflow system which causes displacement of the liquid contained in the top collection tank and exceeding an overflow level into the bottom collection tank; - collecting a condensed liquid during operation of said apparatus in the bottom collection tank; - actuating (200, 300) said condensate discharge pump so as to displace said condensed liquid from the bottom collection tank into the top collection tank; - detecting (400) a low load condition of said condensate discharge pump, actuation of the condensate discharge pump being interrupted (550) upon detection of said low load condition; - performing (100, 600) a measurement of the actuating time (T2) of the condensate discharge pump, with signalling (700) of a full condition of the condensate collection system when this actuating time (T2) exceeds a maximum time (T2lim).