Flow-Through Chemical Sensor for Warewash Machine Detection Accuracy
Find Innovative SolutionsGenerate Solutions
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 automatic alerts and adjustments based on operator input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional chemical sensing methods are used in warewash machines, then the system can detect chemical presence, but the detection accuracy and responsiveness are insufficient
Solution Approach 1:
The patent replaces traditional mechanical or simple electrical sensors with a capacitive sensing system that uses electrical fields to detect chemical presence. The capacitive sensor measures changes in capacitance caused by the dielectric properties of different chemicals, enabling accurate and responsive detection without mechanical moving parts.
Solution Approach 2:
The system detects chemical presence by measuring changes in electrical parameters (capacitance) that occur when chemicals are introduced into the wash chamber. Different chemicals produce distinct capacitance signatures, allowing the system to identify specific chemical types and their presence/absence states with high precision.
2Adaptability or versatility
If the sensor system is designed to work with multiple chemical brands and formulas, then the system becomes more versatile, but the system complexity increases
Solution Approach 1:
The capacitive sensor system is designed with universal applicability to detect multiple types of chemicals (detergent, sanitizer, rinse aid) from different brands and formulas. A single sensor configuration can identify various chemical types by analyzing their unique dielectric properties, eliminating the need for multiple specialized sensors.
Solution Approach 2:
The system handles chemical variability by measuring changes in electrical parameters (capacitance values and patterns) that differ for each chemical type. The controller analyzes these parameter variations to identify chemicals, allowing the system to adapt to different chemical brands and formulas without hardware modifications.
3Speed
If chemical detection is performed continuously, then the responsiveness is improved, but the energy consumption increases
Solution Approach 1:
The capacitive sensor system performs detection periodically rather than continuously, with the controller measuring capacitance at specific intervals or triggered by operational events. This periodic measurement approach maintains detection responsiveness while significantly reducing energy consumption compared to continuous monitoring.
Solution Approach 2:
The sensor system leverages the existing electrical fields and circuitry already present in the warewash machine's chemical delivery system. By using the machine's operational electrical infrastructure to perform sensing functions, the system achieves responsive detection without requiring additional energy-intensive dedicated sensing circuits.
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 optimizing warewash operations by providing accurate chemical presence or absence feedback, adaptable to multiple chemical types through customizable signal frequencies and thresholds.
Implementation Method 1
the sensor connected in a chemical detection circuit via the pair of electrodes... the sensor attenuates the periodic excitation signal according to impedance level of the chemical
Implementation Method 2
A first flow through chemical sensor includes a first fluid passage therethrough and first and second electrodes thereon... the first and second electrodes arranged in a electrode parallel configuration
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.