Fiber Optic Liquid Level Switch for Fast Vessel Level Detection
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Solution Overview
Problem
Conventional liquid-containing vessels lack automated systems for rapidly responding to small changes in liquid levels, necessitating manual adjustments that can be slow and inefficient.
Innovation Solution
A fiber optic liquid level switch assembly that uses LED emitting and detecting components with fiber optic cables to transmit and reflect light through a glass component, activating an electrical switch based on the presence of liquid or gas, allowing for automated adjustments to liquid levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If manual monitoring of liquid levels is used through sight glass ports, then the system structure remains simple, but the response speed to liquid level changes is slow and requires manual intervention
Solution Approach 1:
The patent replaces manual mechanical monitoring with an automated optical detection system. Light emitting components and light detecting components are positioned to send and receive light through the vessel wall at the liquid level location. When liquid reaches the detection point, it blocks or refracts the light, triggering an electrical signal that automatically activates alarms or control systems, eliminating the need for manual sight glass monitoring and dramatically improving response speed.
Solution Approach 2:
The patent introduces light as an intermediary medium to detect liquid levels. Light emitting components transmit light through the vessel wall, and light detecting components receive the light signal. The liquid itself acts as the intermediary that modulates the light signal when it reaches the detection point, providing automated detection without direct mechanical contact between the sensing system and the liquid.
2Extent of automation
If automated liquid level detection systems are implemented, then the response speed and automation level improve, but the device complexity and cost increase
Solution Approach 1:
The patent designs the light emitting and light detecting components to serve multiple functions: they detect liquid levels, trigger alarms, and can activate control systems to adjust liquid levels. The same optical path and detection mechanism are used across different vessel types and liquid levels, reducing the need for multiple specialized components and simplifying the overall system architecture despite the automation achieved.
Solution Approach 2:
The patent uses the vessel wall itself as a transmission medium for light, copying the existing structural element for a new function. The light emitting and detecting components are positioned to utilize the vessel wall as part of the optical path, eliminating the need for separate access ports or complex mounting structures, thereby reducing system complexity while maintaining automation.
3Measurement precision
If light transmission through the vessel wall is used for detection, then the detection accuracy improves, but the system becomes sensitive to environmental factors and installation precision
Solution Approach 1:
The patent positions the light emitting and light detecting components at symmetric locations relative to the vessel wall, creating an equipotential optical path. This symmetrical arrangement ensures that light travels through equal thicknesses of wall material, minimizing variations in light transmission due to wall thickness variations or installation misalignment, thereby maintaining high detection accuracy while reducing sensitivity to installation precision.
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
Enables rapid and automated detection and adjustment of liquid levels in high-temperature and high-pressure environments, enhancing system responsiveness and efficiency.
Implementation Method 1
a first fiber optic cable with a first end portion including a first terminal end connected to the LED emitting component and a second end portion connected to the cable support module with a second terminal end disposed adjacent to the glass component of the sight window assembly. The first fiber optic cable transmits light from the LED emitting component into the vessel through the glass component.
Implementation Method 2
a second fiber optic cable with a first end portion including a first terminal end connected to the LED detecting component and a second end portion connected to the cable support module with a second terminal end disposed adjacent to the glass component of the sight window assembly. The second fiber optic cable transmits light reflected through the glass component to the LED detecting component when gas is present in the vessel at a designated level adjacent to the glass component
Implementation Method 3
an LED emitting component
Implementation Method 4
an LED detecting component
Data Source
AI summary
An assembly is disclosed herein that is configured to detect a liquid level in a liquid-containing vessel, the assembly comprising a first electrical circuit board disposed in a case and including an LED emitting component, an LED detecting component, and a switch-activating component, a sight window assembly configured to be mounted in an opening in a wall of the liquid-containing vessel at a location remote from the case, the sight window assembly including a housing with a first end section supporting a glass component with an apex configured to be disposed proximate the inner side of the wall of the vessel, and a second end section supporting a cable support module, a first fiber optic cable connecting the LED emitting component to the glass component and a second fiber optic cable connecting the LED detecting component to the glass component, the second fiber optic cable transmitting light reflected through the glass component to the LED detecting component when gas is present in the vessel at a designated level adjacent to the glass component, and not transmitting light when liquid is present in the vessel at the designated level adjacent to the glass component. An electrical switch is configured to be in a first position when reflected light is detected by the LED detecting component, and in a second position when reflected light is not detected by the LED detecting component.