Float Level Sensor with Capacitive Fluid for Foam Detection

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Solution Overview

Problem

Existing level sensors struggle to accurately detect the level of content in containers that contain different types of matter, such as waste tanks with liquid and foam, leading to false low-level detections.

Innovation Solution

A level sensor system comprising a flexible cable with a float sensor attached, where the float sensor changes orientation with contact and includes a capacitive sensing device partially filled with conductive fluid, allowing accurate detection of content levels regardless of matter type.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional level sensors (e.g., ultrasound sensors) are used to detect liquid level, then liquid level detection is achieved, but foam or solid matter on top of the liquid is not detected, resulting in false low level detection

Engineering Contradiction:

Improvelevel detection accuracyVSAvoiddetection capability across different matter types

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The float sensor is designed to universally detect all types of content (liquid, foam, solid matter) by floating on or among them. The float mechanism and capacitive sensor work together to provide a single sensor solution that adapts to different matter types, eliminating the need for multiple specialized sensors and resolving the contradiction between measurement precision and adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If a float sensor with conductive fluid is used, then accurate detection of different matter types is achieved, but the device complexity increases compared to simple sensors

Engineering Contradiction:

Improvelevel detection accuracyVSAvoidsensor structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The float mechanism and capacitive sensing elements are merged into a single integrated float sensor assembly. The conductive fluid, float structure, and capacitive plates are combined in one compact device, reducing the need for multiple separate components and simplifying the overall system while maintaining high detection accuracy across different matter types.

Inventive Principle:

Principle #5Merging (Combining)

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 provides accurate and reliable level sensing across different types of content, preventing false readings and ensuring timely detection of threshold levels.

Implementation Method 1

a float sensor, the float sensor configured to be suspended from the cable in the tank, in use, and to change its orientation as it contacts content in the tank

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

The sensing device may be a capacitive sensing device

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS20250198826A1Level sensor

Publication Date: 2025.06.19 BE AEROSPACE INC

AI summary

A level sensor for detecting a level of content in a tank, the level sensor comprising a flexible cable at an end of which is attached a float sensor, the float sensor configured to be suspended from the cable in the tank, in use, and to change its orientation as it contacts content in the tank, and wherein the float sensor is activated to generate a level sense indication according to its orientation.