Conduit-Based Liquid Level Sensing for Slow-Change Containers
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Solution Overview
Problem
Existing liquid level sensing systems face challenges in accurately determining the level and rate of liquid change in containers with slow consumption rates or large volumes, and they struggle to monitor sensor malfunctions effectively.
Innovation Solution
A system comprising a container, a conduit, and a valve, where the conduit is in fluid communication with the container, allowing liquid to enter or exit proportionally, and including level sensors in a measuring conduit for precise measurement and on-board diagnostics to detect sensor malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is placed in a fixed position relative to the container structure, then the system structure is simple, but the measurement precision deteriorates when liquid level changes are very small over time
Solution Approach 1:
The patent divides the sensing system into two independent parts: a fixed sensor assembly and a movable float mechanism. The float moves with liquid level changes while the sensor remains stationary, allowing precise measurement of small level changes without requiring the entire system to be complex or movable.
Solution Approach 2:
The float acts as an intermediary between the liquid level and the fixed sensor. It translates small liquid level changes into larger, more measurable movements or signals that the fixed sensor can detect accurately, thereby improving measurement precision without complicating the fixed sensor installation.
2Measurement precision
If the sensor moves by float mechanism in direct relationship to liquid level, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The system separates the sensing function (fixed sensor) from the level-following function (float mechanism). This segmentation allows each component to be optimized independently: the float handles the complexity of tracking liquid level while the sensor remains simple and fixed.
Solution Approach 2:
Instead of having the sensor move with the liquid level, the invention inverts the approach by having the float move with the liquid level and remain stationary relative to the sensor. This reversal simplifies the overall system while maintaining measurement accuracy.
3Reliability
If conventional sensing systems are used, then the system structure is simple, but the ability to detect sensor failures and monitor proper operation deteriorates
Solution Approach 1:
The system incorporates feedback mechanisms where the float position and sensor readings are continuously monitored and compared against expected values. This feedback loop enables automatic detection of sensor failures or malfunctions without requiring complex external diagnostic equipment.
Solution Approach 2:
The sensing system includes self-diagnostic capabilities where the float mechanism and sensor work together to monitor their own operational status. The system can detect its own failures through built-in reference measurements and consistency checks, reducing the need for external monitoring complexity.
Data Source
AI summary
Systems and methods for sensing an amount of a liquid in a container are provided. A conduit is provided that has a length positioned relative to a portion of the container where a level of the liquid in the container changes when liquid is added to the container or liquid is removed from the container. The conduit is in fluid communication with the container to therefore allow an amount of the liquid to enter the conduit that is proportional to the amount of the liquid in the container. An outlet is provided along with a valve. The valve is in fluid communication with the conduit and the outlet, where the valve is selectable to allow the amount of liquid in the conduit to pass to the outlet, the amount of liquid passing to the outlet proportional to the amount of liquid in the container.