Condensate Pump Float Control With Dual Microswitch Levels
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Solution Overview
Problem
Existing condensate removal pump control systems are inefficient and unreliable due to frequent activation and deactivation near the maximum liquid level, leading to potential overflow and requiring complex and costly bistable microswitches or additional floats, while also lacking effective alarm detection for safety.
Innovation Solution
A control device using a float and pivoting arm to selectively actuate two monostable microswitches, allowing for distinct states to manage pumping between maximum and minimum levels, and triggering an alarm state when the liquid level exceeds the maximum, thereby optimizing pumping cycles and safety without the need for expensive bistable switches or additional floats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a monostable microswitch is used to control the pump at maximum level, then the pump can be activated when the level reaches maximum, but the pump stops too early when level drops slightly below maximum, causing frequent activation cycles
Solution Approach 1:
The control range is segmented into three distinct levels: maximum level (Ma) for pump activation, minimum level (Mi) for pump deactivation, and an intermediate range where the pump continues operating. This segmentation prevents frequent switching by ensuring the pump runs through a stable operating range rather than toggling at a single threshold point.
Solution Approach 2:
The pump is activated in advance when the liquid level reaches the maximum level Ma, before any potential overflow occurs. The pump then continues to operate until the level reaches the predetermined minimum level Mi, ensuring complete emptying and preventing frequent restart cycles.
2Reliability
If a bistable microswitch is used to achieve proper level control, then the pump can be controlled between maximum and minimum levels, but the device becomes more expensive and complex
Solution Approach 1:
The control function is segmented between two monostable microswitches, each handling a specific threshold (maximum and minimum levels). This segmentation allows the use of simpler monostable switches instead of a complex bistable switch, reducing device complexity while maintaining reliable level control.
Solution Approach 2:
Two independent monostable microswitches are combined to achieve the functionality that would otherwise require a single bistable microswitch. This merging approach uses simpler, more reliable components that are easier to maintain and replace, reducing overall system complexity.
3Reliability
If only maximum level detection is provided, then the pump can be activated at maximum level, but the system lacks safety alarm detection for overflow prevention
Solution Approach 1:
The detection system is segmented into two independent detection thresholds: maximum level Ma for pump activation and a higher security level Ns for alarm activation. This segmentation allows each microswitch to handle a specific safety function, providing comprehensive overflow protection without requiring a complex multi-sensor system.
Solution Approach 2:
The two monostable microswitches serve multiple functions: the first microswitch controls pump operation, while the second microswitch provides security alarm detection. This multi-functionality approach uses simple components to achieve both operational control and safety monitoring, avoiding the need for additional specialized sensors.
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 solution provides a safe, reliable, and cost-effective means to control condensate removal pumps, optimizing pumping cycles and ensuring safety by using two monostable microswitches to manage three distinct levels, reducing frequent activation and deactivation issues and providing effective alarm detection.
Implementation Method 1
a float intended to be placed in a tank, capable of moving while following the level of condensates in the tank
Data Source
Figure 1
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Figure 4~5
AI summary
The present invention relates to a device for controlling a condensate lifting pump, comprising: - a float (102) intended to be placed in a tank (20), capable of moving while following the level of condensates in the tank, - an actuating element (130) driven by the movement of said float (102), characterized in that said actuating element is configured and mounted so as to act selectively on first and second microswitches (110, 120) having respectively a first and a second pushbutton (112, 122) movable between two positions, so as to define three distinct states: - an idle state, in which said pump is stopped, said first pushbutton (112) being in a first position ensuring the stopping of said pump and said second push button (122) being in a second position; - an active state, in which said pump operates, said first push button (112) being in a second position ensuring the implementation of said pump, and said second push button (122) remaining in its second position; - an alarm state, in which a safety action is triggered, said first push button (112) remaining in its second position ensuring the implementation of said pump and said second push button (122) being in a first position ensuring the triggering of a safety action.