Float Sensor Accelerometer Pitch Calculation
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Solution Overview
Problem
Existing fluid level sensing systems face challenges with maintenance, installation complexity, reliability, and cost, particularly with floating sensors that are prone to failure due to wiring issues and entanglement, leading to increased troubleshooting difficulties.
Innovation Solution
A fluid level signaling and control system utilizing a sensor float assembly with a three-axis accelerometer to measure gravitational forces, allowing for accurate orientation calculation and communication of fluid levels, which is connected to a remote controller via a serial data protocol, enabling reliable and low-maintenance operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If floating fluid level sensors are used to provide multiple level readings, then measurement precision is improved, but device complexity and maintenance requirements increase due to wiring entanglement and fouling
Solution Approach 1:
The patent replaces mechanical contact-based sensing (potentiometers, mercury switches, rolling ball switches) with non-contact sensing technologies including ultrasonic, microwave, optical, and capacitive sensors. This eliminates wiring entanglement and fouling issues while maintaining the ability to provide multiple discrete level readings through electronic signal processing.
Solution Approach 2:
The patent employs a single multi-functional sensor assembly that can detect multiple fluid levels through various sensing modalities (ultrasonic, microwave, optical, capacitive) rather than requiring separate sensors or complex wiring for each level detection function.
2Adaptability or versatility
If multiple floating sensors are deployed to indicate various fluid levels, then adaptability is improved, but reliability decreases due to wiring fouling and entanglement
Solution Approach 1:
By replacing mechanical contact sensors with non-contact sensing methods (ultrasonic, microwave, optical, capacitive), the system eliminates the primary failure modes of wiring fouling and entanglement, thereby improving reliability while maintaining multi-level detection capability.
Solution Approach 2:
The patent introduces an electronic controller that processes signals from the sensor assembly, acting as an intermediary that translates physical sensor outputs into discrete level indications. This electronic mediation layer isolates the sensing elements from direct mechanical interaction with the fluid and wiring, reducing failure risks.
3Reliability
If stationary fluid level sensors are used to avoid wiring issues, then reliability is improved, but manufacturing cost and maintenance requirements increase
Solution Approach 1:
The patent employs a dynamic floating sensor assembly that moves with fluid level changes, allowing the sensor to self-position at different heights without requiring multiple stationary sensors or complex installation infrastructure. This dynamic approach simplifies installation while maintaining reliability through non-contact sensing.
4Adaptability or versatility
If tethered floating sensors are used to enable movement, then adaptability is improved, but device complexity increases due to tether cable length requirements
Solution Approach 1:
The patent replaces mechanical tether cables with wireless or minimally intrusive connection methods, allowing the floating sensor assembly to move freely without being constrained by cable length or entanglement. This enables full adaptability to fluid level changes while eliminating tether-related complexity.
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 reliable, low-maintenance, and cost-effective fluid level monitoring and control, simplifying installation and troubleshooting by accurately determining fluid levels and executing programmable actions, while minimizing the risk of sensor failure.
Implementation Method 1
Gravity acts to pull the sensor towards the center of the earth while the sensor's buoyancy overcomes this gravitational force
Implementation Method 2
the sensor's buoyancy overcomes this gravitational force when in contact with the fluid medium and forces it away from the earths center
Data Source
AI summary
A fluid level sensing system comprises a sensor float assembly, a sensor control module comprising a sensor processor, and a sensor cable. An accelerometer arranged within the float chamber in a fixed orientation relative to a float axis. The accelerometer is capable of determining movement in at least first and second reference axes. The sensor cable is operatively connected between the float processor and the sensor processor. Movement of the float enclosure relative to the reference point is limited. The accelerometer generates and transfers to the float processor first and second sets of data representative of movement along the first and second reference axes. The float processor generates and transfers to the sensor processor pitch data associated with the float enclosure based on the first and second sets of data. The sensor processor generates a status signal and/or a control signal based on the pitch data.