Integrated Fluid Level Sensor Assembly Using Pressure-Actuated Switching
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Solution Overview
Problem
Existing fluid level sensors are bulky, complex, and require multiple components, increasing the risk of failure and needing additional power supplies, making them unsuitable for all fluid systems.
Innovation Solution
A fluid level sensor assembly with an integrated actuator and switch within a housing, activated by fluid pressure, eliminating the need for a separate power supply and reducing complexity by integrating the sensor directly into the fluid flow system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a float and external switch arrangement is used for fluid level sensing, then the sensor can detect fluid levels, but the assembly becomes bulky and complex with multiple components
Solution Approach 1:
The patent integrates the actuator, switch component, and housing into a single unified sensor assembly that fits within the fluid flow channel. The actuator is positioned to directly engage the switch component when fluid pressure increases, eliminating the need for separate float and external switch components. This merging of components reduces assembly complexity while maintaining reliable fluid level detection functionality.
2Measurement precision
If electronic sensors are used for fluid level detection, then detection capability is improved, but additional power supply is required
Solution Approach 1:
The sensor assembly utilizes the kinetic energy of the flowing fluid itself to activate the switch component. When fluid pressure increases to a predetermined level, the pressure directly moves the actuator into engagement with the switch component, triggering the detection signal without requiring any external power source. The fluid's own energy serves the sensing function.
3Adaptability or versatility
If more components are used in the sensor assembly, then sensing functionality is improved, but the risk of failure increases
Solution Approach 1:
By consolidating the actuator, switch component, and housing into a single integrated assembly with few parts, the patent reduces the number of potential failure points. The streamlined design eliminates multiple connection interfaces and component interactions that could fail, while still providing adaptable sensing functionality for different fluid systems.
4Measurement precision
If a float is designed to engage with an external switch, then level detection is achieved, but the float must be relatively large making it unsuitable for all fluid systems
Solution Approach 1:
The patent extracts the sensing functionality from a large floating component and relocates it to a compact actuator-switch assembly that fits directly within the fluid flow channel. The actuator responds to fluid pressure increases without requiring buoyant floating, enabling precise level detection in compact spaces suitable for various fluid system configurations.
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 assembly is compact, easily integrated, and less prone to failure, offering reliable fluid level detection without additional power requirements.
Implementation Method 1
when the pressure fluid in the fluid flow channel increases to increase the pressure in the sensing flow channel, via the opening, the pressure in the sensing flow channel moves the actuator into engagement with the switch component
Data Source
AI summary
A fluid level sensor assembly includes a first housing part having a fluid inlet and a fluid outlet and a fluid flow channel between the inlet and the outlet. The assembly also includes a sensor housing part formed on or integral with the first housing part and defining a sensing flow channel between a sensor end and a closed end, and has an opening from the sensing flow channel to the fluid flow channel of the first housing part. The assembly also includes level sensor components provided in the sensor flow channel at the sensor end, the level sensor components comprising: an actuator, and a switch component. The actuator and the switch component are arranged in the sensing flow channel such that when the pressure fluid in the fluid flow channel increases to increase the pressure in the sensing flow channel.