Fluid Mixing Sensor Layout With Plastic Conductivity Electrodes
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Solution Overview
Problem
Existing sensor systems for monitoring fluid mixing in automated analyser systems are either too large, expensive, or have metallic electrodes that interact with process liquids, influencing analysis results, and lack efficient conductivity measurement due to complex designs and high costs.
Innovation Solution
A sensor system comprising two vertically arranged level sensors, four horizontally arranged conductivity sensors with conductive plastic electrodes, and a temperature sensor, embedded in a hot melt compound within an injection molded housing, which applies a defined current and measures conductivity without metal interactions, ensuring precise monitoring of fluid levels and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If very precise conductivity sensors with metallic electrodes are used for monitoring fluid mixing, then measurement precision is improved, but object-affected harmful factors worsen due to metal interactions with process liquids
Solution Approach 1:
The patent replaces metallic electrodes with conductive plastic electrodes. The conductive plastic material (such as conductive polymer) serves the same electrical function as metal electrodes but eliminates the harmful chemical interactions between metal and process liquids. This substitution maintains conductivity measurement capability while removing the source of contamination and interference.
Solution Approach 2:
The patent uses composite conductive plastic materials that combine the electrical conductivity needed for measurement with the chemical inertness of plastic. This composite material approach allows the electrode to function electrically while being chemically compatible with aqueous solutions and process liquids, preventing corrosion and contamination.
2Measurement precision
If conventional conductivity sensors with metallic electrodes are used, then conductivity measurement is achieved, but device complexity increases due to additional facilities required for preparation and provision of solutions
Solution Approach 1:
The sensor system is designed to be self-contained and self-sufficient. The conductive plastic electrodes eliminate the need for external metal preparation facilities, and the integrated design with level sensors and temperature compensation allows the system to monitor and adjust its own operation without additional external equipment.
3Manufacturing precision
If precise pumps or manual preparation methods are used for mixing buffer solutions, then mixing precision is improved, but device complexity increases due to additional facilities
Solution Approach 1:
The patent implements a feedback control system where the conductivity sensor continuously monitors the mixed solution's conductivity and provides real-time feedback to the control unit. The control unit adjusts the pump operation to maintain the desired mixing ratio, eliminating the need for extremely precise manual or mechanical mixing while achieving consistent results through closed-loop control.
4Adaptability or versatility
If multiple sensors are integrated in a single device as disclosed in US 2019/056321 A1, then functionality is improved, but device complexity increases
Solution Approach 1:
The patent combines level sensors, conductivity sensors with conductive plastic electrodes, and temperature sensing capabilities into a single integrated sensor system. This merging of functions into one compact device provides versatile monitoring capability while avoiding the complexity of multiple separate sensor systems, achieving economies of scale in both design and installation.
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 sensor system provides cost-effective, reliable, and precise monitoring of fluid levels and conductivity, preventing metal interactions and reducing complexity and costs, while ensuring accurate analysis results.
Implementation Method 1
these sensors usually measure the conductivity of the liquid by means of metallic electrodes that are immersed in the liquid, alternatively there are also inductive sensors. With these, an electrical voltage is coupled into the liquid by means of a coil and the resulting current flow in the liquid is measured with a second coil
Implementation Method 2
an integrated in a sensor device, wherein a plurality of detection arrangements of various types, comprising at least a level-sensing arrangement
Implementation Method 3
possibly also a temperature-sensing arrangement
Data Source
AI summary
A sensor system, particularly for monitoring the mixing of at least two fluids and a method for monitoring the mixture of at least two liquids. The present invention provides a sensor system for fluids, comprising at least two level sensor which are arranged vertically one upon the other on and connected to an electronic circuit board, four electrodes of four conductivity sensors which are arranged horizontally next to each other at the bottom of and connected to the electronic circuit board; and a temperature sensor which is connected to the electronic circuit board; a connector for connecting the electronic circuit board to a controller; wherein the electronic circuit board is embedded in a hot melt compound which is surrounded by an injection molded housing.