Condensate Pump Control Without Float Sensors or Overflow
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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, leading to inefficient energy consumption and potential overflow issues due to their operational protocols.
Innovation Solution
A method that eliminates the need for float-type level sensors by using a condensate discharge pump with a local control board to detect low load conditions and measure actuating time, signaling full conditions without sensors, thereby optimizing energy use and preventing overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a float-type level sensor is used to detect condensate levels, then the full condition of the collection system can be detected, but the manufacturing cost increases and the reliability decreases due to potential jamming
Solution Approach 1:
The patent removes the float-type level sensor from the system entirely. Instead of using a mechanical sensor that is prone to jamming, the invention uses the pump's own operational characteristics (current consumption, actuating time) to detect the full condition of the collection system, thereby extracting the problematic component while maintaining detection capability
Solution Approach 2:
The patent replaces the mechanical float-type level sensor with an electronic control system that monitors the pump's electrical parameters. The control board measures current consumption and actuating time to infer condensate levels, substituting a mechanical detection system with an electronic one that is more reliable and requires fewer moving parts
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 the tank is already empty or nearly empty
Solution Approach 1:
The patent implements a feedback mechanism where the control board continuously monitors the pump's current consumption and actuating time. When the pump encounters air instead of liquid (indicating the tank is empty), the current profile changes, providing feedback to stop the pump operation, thereby avoiding unnecessary energy consumption while maintaining emptying productivity
Solution Approach 2:
The patent makes the pump operation dynamic rather than static. Instead of running for a fixed predetermined time regardless of conditions, the pump operation is continuously adjusted based on real-time monitoring of liquid presence through electrical parameter analysis, allowing the system to adapt its operation to actual tank conditions
3Loss of information
If the condensate discharge pump runs for a predetermined time interval, then the bottom tank can be emptied, but the system cannot detect full conditions without a float sensor
Solution Approach 1:
The patent makes the control board multi-functional. The same control board that manages pump activation and timing also monitors electrical parameters to detect the full condition of the collection system. This universal approach eliminates the need for separate detection hardware while preventing information loss about system status
Solution Approach 2:
The patent enables the pump system to self-diagnose its operational status. By monitoring its own current consumption and actuating time, the pump system can independently determine when the collection system is full without external sensors, allowing the system to serve itself in terms of status detection and control
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 interrupting pump operation when the collection tank is empty, preventing unnecessary energy use and potential overflows.
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
AI summary
A method for collecting condensate inside an apparatus, including: providing a condensate collection system with bottom and top collection tanks; a condensate discharge pump to displace liquid from the bottom collection tank to the top collection tank; and an overflow system which displaces the liquid contained in the top collection tank that exceeds an overflow level into the bottom collection tank; collecting a condensed liquid in the bottom collection tank; actuating the condensate discharge pump to displace the condensed liquid from the bottom collection tank into the top collection tank; detecting a low load condition of the condensate discharge pump, actuation of the condensate discharge pump being interrupted upon detection of the low load condition; the actuating time (T2) of the condensate discharge pump, with signalling of a full condition of the condensate collection system when this actuating time (T2) is equal or larger than a maximum time (T2lim).