Flow-Through Chemical Sensor for Multi-Formula Warewash Detection
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Solution Overview
Problem
Existing warewash machines lack accurate and responsive sensing mechanisms to detect the presence or absence of chemicals, such as detergent, sanitizer, and rinse aid, which are essential for optimal operation, and these systems often fail to accommodate multiple chemical brands and formulas effectively.
Innovation Solution
The implementation of flow-through chemical sensors with electrodes configured in parallel or opposed orientations, integrated into chemical feed lines, which apply a periodic excitation signal to detect chemical presence by attenuating the signal based on impedance levels, and a controller that adjusts signal frequency and threshold settings according to the identified chemical type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow-through chemical sensors with parallel and opposed electrode configurations are implemented, then measurement precision for detecting multiple chemical brands is improved, but device complexity increases
Solution Approach 1:
The sensor system is divided into multiple electrode configurations (parallel and opposed) within separate flow paths, allowing each configuration to detect different chemical properties independently, thereby improving overall measurement precision while maintaining manageable complexity through modular design
Solution Approach 2:
The sensor system incorporates multiple electrode configurations that can detect various chemical brands and formulas using the same basic sensor structure, making the device universal for different chemical types while improving measurement precision across all chemical varieties
2Adaptability or versatility
If multiple electrode configurations are used to detect different chemical properties, then adaptability to various chemical brands and formulas is improved, but manufacturing precision requirements increase
Solution Approach 1:
Different electrode configurations are placed in separate flow paths, allowing each to be manufactured and positioned independently with standard tolerances, reducing the cumulative precision requirements while maintaining adaptability to various chemicals
Solution Approach 2:
Each electrode configuration is optimized for specific chemical detection requirements, with local variations in electrode geometry and positioning that match the specific detection needs of different chemical types, improving adaptability without requiring uniform high precision across the entire device
3Ease of operation
If flow-through sensors with offset electrode configurations are implemented, then ease of operation for detecting chemical presence is improved, but device complexity increases
Solution Approach 1:
The sensor system uses multiple simple flow paths with offset electrode configurations rather than one complex configuration, allowing each path to independently detect chemical presence in a straightforward manner, improving ease of operation while distributing complexity across multiple simple components
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 precise detection of chemicals, ensuring timely replenishment and accommodating various chemical brands, thereby optimizing warewash machine operations and improving user experience by providing accurate alerts and adaptable chemical detection.
Implementation Method 1
apply a periodic excitation signal to detect chemical presence by attenuating the signal based on impedance levels
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A flow through chemical sensor includes a housing having a through passage along which chemical can flow, a sidewall of the housing having first and second openings that communicate with the through passage. A first electrode is mounted on the housing and aligned with the first opening, the first electrode of a plate configuration with a unitary depression that extends through the first opening and to a peripheral edge of the through passage. A second electrode is mounted on the housing and aligned with the second opening, the second electrode of a plate configuration with a unitary depression that extends through the second opening and to the peripheral edge of the through passage. A method of detecting presence or absence of chemical is also provided.