Conductivity Sensor for Beverage Dispenser Air Bubble Detection
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Solution Overview
Problem
Beverage dispensers face challenges in accurately sensing fluid ingredient levels, leading to costly pump replacements and incorrect determination of empty ingredient containers due to air bubbles, which affects beverage quality and operational efficiency.
Innovation Solution
Incorporating a resistance or conductivity sensor within each fluid path of the dispenser, using a pair of electrodes to measure electrical conductivity, allowing for accurate detection of air bubbles and preventing false positives, thus enabling more reliable and cost-effective monitoring of ingredient levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pressure sensor is used to detect air bubbles in the fluid path, then the sensing capability is provided, but the sensor fails when gaskets break down due to high concentrations of acids and salts
Solution Approach 1:
The patent replaces the pressure sensor (mechanical/electrical system) with an optical sensor that uses light transmission through the fluid path to detect air bubbles. This substitution eliminates the mechanical components (gaskets, seals) that are susceptible to corrosion from acids and salts, thereby resolving the reliability issue while maintaining the air bubble detection function.
2Measurement precision
If an optical sensor is used to detect air bubbles, then small air bubbles can be detected, but false positives occur when small air bubbles are present in the fluid path
Solution Approach 1:
The patent implements a feedback mechanism where the optical sensor continuously monitors the fluid path and the system distinguishes between transient small air bubbles (normal operation) and sustained air bubble presence (empty container condition). The controller uses this feedback to determine when to trigger the empty container alert, reducing false positives while maintaining detection sensitivity.
3Ease of operation
If conventional sensors are used to detect empty ingredient containers, then the basic sensing function is provided, but accurate sensing is difficult due to various factors
Solution Approach 1:
The patent introduces an intermediary optical sensing system that measures light transmission properties of the fluid in the container. This intermediary measurement approach provides a more reliable and accurate indicator of empty container status compared to direct pressure or flow sensing, as it can detect changes in fluid presence and characteristics without being affected by the same interfering factors.
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 enhances the accuracy of ingredient level sensing, reduces unnecessary pump replacements, and minimizes the loss of beverages that do not meet flavor specifications, thereby reducing operational costs and improving customer satisfaction.
Implementation Method 1
an electrical conductivity sensor configured to sense an electrical conductivity of the fluid ingredient flowing through the conduit
Data Source
AI summary
A beverage dispenser for dispensing beverages and process may include a fluid container containing a fluid ingredient, a conduit fluidly connected to the fluid container, and an electrical conductivity sensor. The electrical conductivity sensor may be (i) fluidly connected to the conduit, and (ii) configured to sense an electrical conductivity of the fluid ingredient flowing through the conduit. The electrical conductivity sensor may further be configured to output (i) a first electrical signal in response to sensing an air bubble, and (ii) a second electrical signal in response to not sensing an air bubble.