Fluid Level Sensor Assembly with Integrated Tubular Housing
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Solution Overview
Problem
Existing fluid level sensors for controlling motorized valves are bulky, heavy, and unsuitable for detecting non-conductive fluids, leading to inaccurate level detection and potential underpressure issues due to contamination and residual water detection.
Innovation Solution
A compact tubular housing with an axial flow channel and a sensor channel, where a first sensor part moves under fluid pressure to communicate with a second sensor part at a predetermined level, enabling accurate detection of fluid levels without the need for power and suitable for all fluid types, including non-conductive fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conductive sensor device is provided in a branch of a wye fitting to detect water level, then the sensor can detect water level by conductivity, but the sensor becomes contaminated by particles and debris in the fluid and cannot detect non-conductive fluids
Solution Approach 1:
The sensor is extracted from direct contact with the fluid by placing it in a sensor chamber separated by a membrane. The membrane allows fluid pressure to act on the sensor while preventing direct contact, thus eliminating contamination issues while maintaining level detection capability.
Solution Approach 2:
A membrane is introduced as an intermediary between the fluid and the sensor. This membrane transmits fluid pressure to the sensor while blocking direct contact, preventing contamination and enabling reliable detection of both conductive and non-conductive fluids.
2Measurement precision
If a wye fitting with branch channel is used to mount the sensor, then the sensor can be positioned out of main flow, but the assembly becomes bulky, heavy, and takes up large area
Solution Approach 1:
The sensor housing is merged with the valve body, eliminating the need for separate wye fittings and external mounting structures. This integration reduces the overall assembly size, weight, and space requirements while maintaining level detection functionality.
Solution Approach 2:
The sensor chamber is nested within the valve body structure, with the sensor positioned inside the housing. This nested arrangement allows the sensor assembly to occupy minimal space and reduces overall weight compared to external mounting configurations.
3Measurement precision
If the sensor is placed in a branch of the wye fitting, then it can detect fluid level, but residual water droplets in the branch cause false detection and underpressure upstream
Solution Approach 1:
The sensor is extracted from the fluid path where residual droplets accumulate. By positioning the sensor in a separate chamber accessed through a membrane, the sensor no longer encounters residual water droplets that would cause false activation, eliminating the harmful effect of premature valve opening.
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 solution provides a lightweight, compact, and accurate fluid level sensor assembly that effectively controls motorized valves, preventing underpressure and ensuring precise fluid management across various fluid types, including non-conductive fluids.
Implementation Method 1
a first sensor part located in the sensor channel such that the first sensor part can move axially within the sensor channel responsive to pressure of the fluid in the flow channel acting on the first sensor part in the sensor channel
Data Source
AI summary
A fluid level sensor assembly includes a tubular housing arranged to be fitted into a fluid flow path of a system between a fluid line an inlet to a valve (1′), wherein the tubular housing defines an axial flow channel extending through the tubular housing from a first end to a second end, along an axis A, for fluid to flow from the fluid line of the system to the valve inlet, the tubular housing further comprising a sensor channel extending from the second end of the flow channel towards the first end substantially parallel to, and in fluid communication with the axial flow channel, wherein the assembly further comprises first and second sensor parts located in the sensor channel that communicate with each other.