Sensor system and integrated heater-sensor for measuring and controlling performance of a heater system
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Solution Overview
Problem
Conventional heating systems with multiple independent sensors are complex and can only detect large incremental changes, making them inefficient for precise measurement of fluid characteristics like temperature and level.
Innovation Solution
A fluid sensor system with a probe featuring a resistive heating element and temperature sensors, which creates a temperature differential to detect fluid level and measure temperature, and a control system that determines performance characteristics based on electrical responses from these elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple independent sensors are used to measure different performance characteristics, then measurement coverage is improved, but device complexity increases significantly
Solution Approach 1:
The patent combines multiple sensor functions (temperature sensing, fluid level detection, and heater elements) into a single integrated probe assembly. The probe contains both temperature sensors and resistive heating elements that serve dual purposes as both heaters and sensors, eliminating the need for multiple separate sensor devices while maintaining comprehensive measurement capabilities
Solution Approach 2:
The resistive heating element serves multiple functions: it acts as a heater to create temperature differential, and simultaneously functions as a sensor by measuring its own electrical resistance to detect fluid level. This multi-functionality reduces the number of components needed while achieving comprehensive performance characterization
2Measurement precision
If multiple independent sensors are used to measure different performance characteristics, then measurement capability is improved, but the system can only detect large incremental changes
Solution Approach 1:
The patent utilizes electrical resistance as a sensitive parameter that changes with temperature and fluid level. By monitoring small changes in the electrical resistance of the heating element and temperature sensor outputs, the system can detect fine incremental changes in fluid level and temperature, overcoming the limitation of detecting only large incremental changes
3Measurement precision
If a resistive heating element is used to create temperature differential for fluid detection, then fluid level detection precision is improved, but energy consumption increases
Solution Approach 1:
The resistive heating element is designed to serve dual purposes: it heats the probe to create temperature differential for fluid detection, and simultaneously acts as a temperature sensor by measuring its own resistance changes. This eliminates the need for separate heating and sensing components, reducing overall energy consumption while maintaining detection precision
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
Enables precise measurement of fluid level and temperature, reducing system complexity and improving the ability to detect fluid presence, thereby enhancing the control of heating systems.
Implementation Method 1
the resistive heating element is operable as a heater to create a temperature differential along the length of the probe to detect the fluid
Implementation Method 2
The fluid temperature sensor is configured to measure a fluid temperature
Implementation Method 3
the ambient temperature sensor is a thermocouple
Implementation Method 4
the probe further comprises a resistance temperature detector RTD
Data Source
AI summary
A fluid sensor system detects one or more performance characteristics of a heating system that heats a fluid. The sensor system includes a probe having a finite length a portion of which is to be immersed in the fluid. The probe includes a resistive heating element and a fluid temperature sensor for measuring one or more performance characteristics, wherein the fluid temperature sensor is configured to measure a fluid temperature, and the resistive heating element is operable as a heater to create a temperature differential between the fluid and air to detect the fluid, and as a sensor to measure a fluid level.