Flow-Through Chemical Sensor for Accurate 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 require adjustments for different chemical brands or formulas.
Innovation Solution
The implementation of flow-through chemical sensors with specific electrode configurations and orientations within the chemical feed lines of warewash machines, connected to a chemical detection circuit that applies a periodic excitation signal and evaluates impedance levels to determine chemical presence, allowing for operator alerts and automatic frequency/threshold adjustments based on chemical type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow-through chemical sensors with electrode configurations are implemented, then measurement precision of chemical presence is improved, but device complexity increases
Solution Approach 1:
The sensor is divided into multiple electrodes (first electrode, second electrode, third electrode) with different configurations (parallel and opposed arrangements). Each electrode segment serves a specific detection function, allowing the system to achieve high measurement precision through multiple measurement points while keeping each individual electrode simple in structure.
Solution Approach 2:
Different electrode configurations (parallel vs. opposed) are applied at different locations within the fluid passage to detect different chemical properties. The parallel electrodes detect one aspect of chemical presence while the opposed electrodes detect another aspect, providing localized quality enhancement for comprehensive chemical detection.
2Adaptability or versatility
If multiple electrode configurations are used in sensors, then adaptability to different chemical brands and formulas is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sensor incorporates multiple electrode configurations (parallel and opposed) that can detect various chemical properties across different chemical brands and formulas. This multi-functional design allows a single sensor to universally detect different types of chemicals (detergent, sanitizer, rinse aid) without requiring multiple specialized sensors, achieving adaptability while the standardized housing design helps manage manufacturing precision requirements.
3Productivity
If chemical sensors are integrated into chemical flow paths, then productivity of warewash operation is improved, but ease of operation decreases
Solution Approach 1:
The chemical sensor is merged with the chemical flow path by integrating the electrodes directly into the chemical delivery system. The sensor housing is designed to be part of the flow path structure, combining the sensing function with the fluid transport function. This integration enables continuous monitoring that improves productivity, while the design incorporates accessible mounting points and standardized connections to maintain ease of operation.
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 multiple chemical brands, thereby optimizing warewash operations and improving user experience.
Implementation Method 1
a chemical sensor, system and method for detecting the presence or absence of chemicals used for ware cleaning operations
Data Source
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.