Contactless Level Sender Using Magnetic Driven Member
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Solution Overview
Problem
Existing level senders for fluid tanks face challenges in accurately determining fluid levels due to hysteresis and wear, particularly in contact-based systems, which can lead to inaccurate readings and reduced reliability.
Innovation Solution
A level sender system utilizing a contactless sensor and a diametric magnet-driven member that axially rotates within a fluid tank, allowing for precise angular position detection without physical contact, minimizing hysteresis and wear, and providing a reliable fluid level indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact-based sensing mechanisms are used to determine fluid level, then the system can provide direct mechanical coupling and signal transmission, but hysteresis and wear occur leading to inaccurate readings and reduced reliability
Solution Approach 1:
The patent replaces contact-based mechanical sensing mechanisms with a contactless magnetic field-based sensor system. The float assembly with magnet interacts with the sensor through magnetic coupling without physical contact, eliminating wear and hysteresis while maintaining reliable signal transmission for accurate fluid level measurement
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the float assembly and the sensor. The magnet on the float assembly generates a magnetic field that couples with the sensor, enabling signal transmission without direct mechanical contact, thus resolving the contradiction between reliability and measurement precision
2Measurement precision
If contactless sensing is implemented, then hysteresis and wear are minimized improving accuracy, but system complexity increases due to additional components
Solution Approach 1:
The float assembly serves multiple functions: it provides buoyancy to track fluid level, carries the magnet for contactless sensing, and acts as the moving component that translates fluid level changes into positional changes detectable by the sensor. This multi-functionality reduces the need for separate components, managing system complexity while achieving high measurement precision
3Ease of manufacture
If a float assembly with direct coupling is used, then the mechanism is simple and robust, but friction and wear at coupling points reduce measurement accuracy over time
Solution Approach 1:
The patent eliminates mechanical coupling friction and wear by replacing direct mechanical connections with magnetic field-based sensing. The float assembly moves freely without friction-prone couplings, and the sensor detects position through magnetic interaction, maintaining manufacturing simplicity while ensuring long-term measurement accuracy
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 system offers improved accuracy and reduced maintenance requirements by minimizing hysteresis and wear, providing precise fluid level measurements with high resolution and resistance to environmental factors like tank slosh and tilt.
Implementation Method 1
A contactless sensor is positioned within proximity of the diametric magnet-driven member
Implementation Method 2
A float assembly is configured for carrying and axially rotating the driven member
Implementation Method 3
A float arm is coupled to a float at a first end and is coupled to the driven member at a second end
Data Source
AI summary
A level sender for a tank includes a sensor device. A driven member is associated with a float assembly. The sensor device is adapted to determine a level of fluid within the tank based on an angular position of the driven member. A float arm is coupled to a float at a first end and is coupled to the driven member at a second end.