Infrared Liquid Level Detection in PEM Separator
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Solution Overview
Problem
Current liquid/gas separator devices for water and hydrogen, particularly in PEM cell applications, face issues with mechanical complexity, precision machining requirements, lack of functional failure detection, vulnerability to obstructions, and reliability under vibrations, leading to potential leaks and maintenance challenges.
Innovation Solution
A separator device utilizing a spherical ball float and infrared sensors with a microprocessor-controlled solenoid valve to manage water and hydrogen separation, ensuring precise control and detection of operational anomalies, with optional filter placement to prevent obstructions, and electronic monitoring for reliability and maintenance reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a float with rubber portions and conical structures is used for liquid level control, then liquid level regulation is achieved, but mechanical precision and reliability deteriorate due to machining complexity and susceptibility to obstruction
Solution Approach 1:
The patent replaces the mechanical float system with rubber portions and conical structures with an optical detection system using infrared sensors. The sensors detect the liquid level by sensing the change in infrared transmission when the liquid surface blocks the beam, eliminating mechanical moving parts and their associated reliability issues.
Solution Approach 2:
The patent introduces infrared light as an intermediary between the liquid level and the detection system. The infrared sensors transmit light through the transparent tank wall, and the liquid level is detected by the interruption of this light beam, providing a non-contact measurement method that avoids mechanical obstruction problems.
2Loss of information
If transparent tank material is used for visual monitoring, then observation capability is improved, but manufacturing precision requirements worsen due to need for optical clarity and sensor alignment
Solution Approach 1:
The patent uses the transparent tank wall as an intermediary for optical signal transmission. The infrared sensors are positioned externally, and the tank wall itself serves as the medium through which the infrared light passes, eliminating the need for separate optical windows and reducing manufacturing complexity.
Solution Approach 2:
The transparent tank material serves a dual function: it provides structural containment for the liquid/gas mixture and simultaneously acts as an optical window for infrared sensor detection. This self-service approach eliminates the need for separate optical access components and their associated precision mounting requirements.
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 reliable, low-maintenance, and vibration-resistant separation system with enhanced precision and detection capabilities, preventing leaks and allowing for continuous operational monitoring, thus ensuring consistent hydrogen and water separation without the need for frequent maintenance.
Implementation Method 1
A ball float 56 is present in the tank 52 and free to float on the water which accumulates
Implementation Method 2
two infrared transmitters 70, 72 (e.g. IR LEDs), and two infrared sensors or receivers 74, 76 (e.g. IR photodiodes), arranged in pairs on a horizontal axis so that a sensor receives the infrared beam from the respective transmitter
Implementation Method 3
The top of the tank 52 communicates rather by means of a hydrogen outflow duct 62 towards hydrogen collection means (not shown)
Data Source
Figure 1~2
Figure 3~4
AI summary
A liquid/gas separator device (50) is described comprising a container (52) to contain the mixture of liquid and gas. The device is characterised by the fact of comprising - measurement means (70, 74) for measuring, or reaching of, a level of liquid in the container; - valve means (60) positioned on an outflow for the liquid from the container; - control means (78) cooperating with the measuring means so as to receive the measurement of the level of liquid and adapted to act consequentially on the valve means to maintain a predefined level of liquid in the container.