Fluid Vessel Heating Control with Level Sensing and Overheat Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heating control systems for fluid vessels are complex, prone to overheating, and lack visual fluid level monitoring, which can damage heating elements and fluids.
Innovation Solution
A simplified heating control system with a low fluid level sensor, indicators for fluid levels, and a control circuit that includes relays and a temperature sensor to manage heating and prevent overheating, suitable for mobile applications like portable fluid delivery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a temperature sensor with periodic on/off duty cycle is used for heating control, then heating control is provided, but the control circuitry becomes complex and the fluid temperature varies significantly in different parts of the vessel
Solution Approach 1:
The patent extracts the temperature sensing function from a separate complex control circuit and integrates it directly into the heating element assembly. The temperature sensor is positioned in direct thermal contact with the heating element, allowing local temperature monitoring and control without complex centralized circuitry. This extraction of the sensing function to the point of action simplifies the overall control system.
Solution Approach 2:
The patent implements local feedback control where the temperature sensor continuously monitors the fluid temperature adjacent to the heating element and provides real-time feedback to the control circuit. This feedback mechanism allows the system to adjust the heating duty cycle based on actual local temperature conditions, preventing both overheating and excessive complexity in the control logic.
2Power
If heating is applied without fluid level monitoring, then heating function is provided, but the fluid may be overheated and heating elements damaged
Solution Approach 1:
The patent incorporates a fluid level sensor that activates before the heating element operates. The sensor detects the presence of fluid at a predetermined level and only then permits the heating function to engage. This preliminary detection and conditional activation prevent overheating and damage by ensuring fluid is present before heating begins, enhancing system reliability.
Solution Approach 2:
The patent introduces a fluid level sensor as an intermediary between the power source and the heating element. This intermediary component monitors fluid levels and controls the activation of the heating element accordingly. The sensor acts as a protective mediator that prevents direct activation of heating without adequate fluid, thereby protecting both the fluid and heating elements from damage.
3Device complexity
If no visual monitoring of fluid level is provided, then device simplicity is maintained, but user awareness of fluid level is insufficient
Solution Approach 1:
The patent employs visual indicators that change color or illumination state based on fluid level detection. The fluid level sensor is coupled with visual indicators that provide immediate visual feedback to the user about the current fluid level. This use of color or light changes communicates fluid level information intuitively without adding significant complexity to the device.
Solution Approach 2:
The patent replaces complex mechanical level indication systems with electronic or optical sensing and indication mechanisms. The fluid level sensor uses electrical or optical fields to detect fluid presence, and the visual indicators use LEDs or similar components to display level information. This substitution reduces mechanical complexity while improving the reliability and clarity of fluid level information delivery to the user.
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 effectively prevents overheating of fluids and protects heating elements while providing visual monitoring of fluid levels, resulting in a more user-friendly and efficient heating control solution.
Implementation Method 1
a temperature sensor with a periodic on/off duty cycle determined by the deviation of the sensed temperature from a predetermined set point
Implementation Method 2
The control circuitry in previous heating control systems of the type, is typically complex. In addition, the temperature in different parts of the fluid vessel varies significantly
Implementation Method 3
previous heating control systems do not employ visual monitoring of the level of the fluid in the fluid vessel
Data Source
AI summary
A heating control system for controlling heating of a fluid within an associated fluid vessel includes a first sensor responsive to a low fluid level in the fluid vessel and a second sensor responsive to a temperature of the fluid within the fluid vessel. The heating control system also includes a control circuit electrically connected with the first sensor and the second sensor to control electrical power to a heating unit for heating the fluid within the fluid vessel. The control circuit allows electrical power to be connected to the heating unit upon a first predetermined condition of the first sensor and a first predetermined condition of the second sensor. The control circuit disconnects power to the heating unit upon either a second predetermined condition of the first sensor or a second predetermined condition of the second sensor.