Evaporator Pan Thermistor Control to Replace Mechanical Float Switches
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Solution Overview
Problem
Existing evaporator drip pan systems rely on mechanical switches or floats to manage liquid levels, which are prone to mechanical failure and inaccurate readings due to numerous moving parts, leading to inefficiencies in liquid removal and potential overheating.
Innovation Solution
An evaporator pan system incorporating a thermistor and a controller to detect current changes, activating a heating element when a threshold current is met to evaporate liquid, reducing the need for mechanical components and enhancing accuracy in liquid level detection and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical switches or floats are used to detect liquid level, then liquid level indication is achieved, but mechanical failure and inaccurate readings occur due to numerous moving parts
Solution Approach 1:
The patent replaces mechanical switches and floats with a thermistor-based electrical sensing system. The thermistor detects liquid level through electrical resistance changes when contacted by liquid, eliminating moving parts and improving reliability. The controller processes electrical signals from the thermistor to determine liquid level, substituting mechanical detection with an electrical field-based approach.
Solution Approach 2:
The thermistor serves as an intermediary element between the liquid and the control system. Instead of direct mechanical contact, the thermistor's electrical properties change in response to liquid contact, providing indirect but reliable liquid level information to the controller without requiring mechanical moving parts.
2Productivity
If mechanical switches or floats are used to manage liquid levels, then liquid removal control is achieved, but mechanical failure leads to inefficiencies in liquid removal
Solution Approach 1:
The patent replaces mechanical liquid level control switches with an electrical sensing and control system. The thermistor provides continuous electrical feedback to the controller, enabling reliable and efficient liquid removal control without the mechanical failures that plague traditional systems.
Solution Approach 2:
The thermistor provides continuous electrical feedback to the controller about liquid level conditions. This feedback loop enables the controller to make real-time decisions about liquid removal operations, improving efficiency and reliability compared to mechanical systems that may fail to provide accurate feedback.
3Ease of operation
If mechanical components are used in the evaporator pan system, then liquid level management is achieved, but system cost and complexity increase
Solution Approach 1:
The patent replaces complex mechanical liquid level management components with a simpler electrical system consisting of a thermistor and controller. This substitution reduces the number of moving parts and mechanical components while maintaining or improving liquid level management capability.
Solution Approach 2:
The thermistor serves multiple functions: it acts as both a temperature sensing element and a liquid level detection probe. This multi-functionality reduces the overall component count and simplifies the system compared to dedicated mechanical level switches and temperature sensors.
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 reliably and efficiently indicates liquid levels, automatically removes excess liquid, and prevents overheating, with reduced mechanical components and lower costs, while maintaining a compact profile and improved reliability.
Implementation Method 1
The thermistor may be positioned at least partially within the evaporator pan. The controller includes at least one data processor and at least one memory storing instructions, which when executed by the at least one data processor, are configured to cause operation. The operations may include detecting a first current passing through the thermistor.
Implementation Method 2
The heating element is configured to heat a liquid within the evaporator pan to cause evaporation of the liquid.
Implementation Method 3
The heating element is configured to heat a liquid within the evaporator pan to cause evaporation of the liquid.
Data Source
AI summary
An evaporator pan system includes an evaporator pan, a heating element positioned at least partially within the evaporator pan, a thermistor positioned at least partially within the evaporator pan, and a controller coupled to the heating element and the thermistor. The controller detects a first current passing through the thermistor. The controller further determines the first current meets a threshold current, indicating a presence of a threshold volume of liquid within the evaporator pan. The controller further activates the heating element to cause evaporation of at least a portion of the liquid within the evaporator pan.