Contactless Liquid Level Sensor for Vacuum Priming Systems
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Solution Overview
Problem
Conventional vacuum priming systems for pumps are susceptible to damage under positive head conditions and require frequent maintenance, especially when handling contaminated or corrosive fluids, and they struggle with liquid surges and debris in the priming liquid, leading to inaccurate responses and inefficient operation.
Innovation Solution
A contactless sensing system, such as ultrasonic sensors, is used to detect liquid levels in the vacuum chamber, eliminating exposed moving parts and enabling the vacuum pump to be disabled when necessary, combined with a baffle system to stabilize liquid flow and a dry scroll vacuum pump to prevent damage, and the exhaust air is directed into the engine intake to burn off contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If float switches are used to detect liquid level in vacuum chamber, then the system can control vacuum pump operation, but the float switches are susceptible to damage from liquid surges and require frequent maintenance
Solution Approach 1:
The patent replaces mechanical float switches with a capacitive liquid level sensor that has no moving parts. The sensor uses electrical capacitance changes to detect liquid level, eliminating mechanical components that are susceptible to damage from liquid surges and contamination. This substitution directly resolves the contradiction by improving reliability while reducing maintenance requirements.
2Reliability
If vacuum pump operates continuously to prime pump, then priming function is maintained, but liquid can flood into vacuum pump under positive head conditions causing damage
Solution Approach 1:
The patent implements a feedback control system where the capacitive sensor continuously monitors liquid level in the vacuum chamber and signals the controller to start/stop the vacuum pump accordingly. This feedback mechanism ensures the pump operates only when needed, preventing liquid flooding while maintaining reliable priming function. The controller receives real-time level information and adjusts pump operation to avoid harmful conditions.
3Measurement precision
If conventional sensors with exposed moving parts are used, then liquid level can be detected, but the sensors become contaminated by corrosive and contaminated liquids
Solution Approach 1:
The patent replaces mechanical float switches with a capacitive sensing system that detects liquid level through electrical field changes without mechanical contact. The capacitive sensor can be positioned to monitor liquid level through chamber walls or with minimal exposure, preventing contamination from corrosive and contaminated liquids while maintaining accurate detection.
4Productivity
If vacuum pump is designed for high capacity operation, then priming speed is improved, but the pump is more vulnerable to damage from liquid surges
Solution Approach 1:
The patent uses feedback control from the capacitive sensor to regulate the operation of the high-capacity vacuum pump. The controller monitors liquid level continuously and shuts down the pump before liquid can surge into it, allowing the use of a high-capacity pump for fast priming while protecting it from damage through intelligent 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
The solution reduces the risk of damage, improves maintenance efficiency, enhances response accuracy, and ensures efficient operation even with contaminated fluids, while the baffle system stabilizes liquid flow and the engine intake burns off contaminants, improving safety and efficiency.
Implementation Method 1
The sensing means may comprise one or more sensors, which may be contactless and/or emit and/or receive mechanical or acoustic and/or electromagnetic waves. The sensing means may comprise an echo-based or reflection-based sensing or measurement means, for example an acoustic, e.g. ultrasonic...
Implementation Method 2
a vacuum pump for evacuating air from the suction line to allow fluid to be drawn for the main pump intake
Implementation Method 3
the exhaust air is directed into the engine intake to burn off contaminants
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
A vacuum priming system (2) for priming the liquid pump (3) of a pumping system (1), which is powered by an internal combustion engine (4) and controlled by a controller (5). The priming system (2) includes a well chamber (20), a vacuum chamber (21) in fluid communication with the well chamber (20), a vacuum pump (24) with an air inlet (24a) fluidly connected to an air outlet (21a) of the vacuum chamber (21) and a contactless sensor (22) mounted at the top of the vacuum chamber (21) for detecting a liquid level therein. The controller (5) is configured to disable the vacuum pump (24) when a predetermined liquid level in the vacuum chamber (21) is detected by the sensor (22). The vacuum pump (24) also has an air outlet (24b) in fluid communication with an air intake (40) of the engine (4).