Inverted Cup Fluid Level Sensor for Sump Pump Reliability
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Solution Overview
Problem
Conventional backup sump pumps face reliability issues due to the lack of effective fluid level sensing mechanisms, particularly with mechanical float switches that can degrade from residue buildup, debris, and mechanical failures, leading to inefficient operation during power outages when water accumulation is critical.
Innovation Solution
A fluid level sensor system utilizing an inverted cup connected to a pressure transducer, which measures pressure changes to control the speed of the sump pump, providing a reliable and efficient means to manage water levels in sump pits during power outages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a mechanical float switch is used to sense fluid level, then the device complexity is reduced compared to mercury switches, but the reliability deteriorates due to moving parts that can become misaligned, damaged, corrode, or fail from electrical arcing
Solution Approach 1:
The patent replaces the mechanical float switch system with a pressure transducer-based sensing system. The pressure transducer measures pressure changes in the sump pit to determine fluid level, eliminating all mechanical moving parts including the float, hinge, and magnetic components. This substitution of mechanical sensing with electronic pressure measurement resolves the reliability issues caused by mechanical wear, misalignment, and corrosion while maintaining simple device architecture.
2Device complexity
If the float is positioned in the liquid to be sensed, then the sensing mechanism is simplified, but the reliability deteriorates due to residue buildup and floating debris causing the switch to degrade and fail
Solution Approach 1:
The patent extracts the sensing element (pressure transducer) from direct contact with the liquid environment. Instead of placing the sensing component in the water where it would accumulate residue and debris, the system measures pressure changes through the air space above the liquid. This extraction of the sensing element from the harmful liquid environment eliminates the reliability problems caused by contamination while keeping the sensing mechanism simple.
3Adaptability or versatility
If a backup sump pump is installed with discharge connecting into the pipe between discharge and sump pit surface, then the installation flexibility is improved, but the ease of manufacture deteriorates due to complex pipe cutting, removal, and reinstallation procedures
Solution Approach 1:
The patent enables the backup sump pump to automatically determine and adapt to the existing discharge pipe configuration without requiring manual intervention for pipe modification. The pressure transducer senses the fluid level and controls the pump operation based on the actual system state, allowing the pump to serve itself by adapting to various installation configurations without requiring complex pipe cutting, removal, and reinstallation procedures.
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 system ensures reliable operation of backup sump pumps by accurately sensing fluid levels and adjusting pump speed, maintaining efficient water management even during severe weather conditions, thereby preventing water accumulation and damage.
Implementation Method 1
an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space... An inner pressure tube can extend from the inner air space and through the sealed top... A pressure transducer can be connected to the inner pressure tube
Implementation Method 2
An ambient pressure tube can be included, with an open end of the ambient pressure tube being positioned near the sealed top. A pressure transducer can be connected to the inner pressure tube and the ambient pressure tube
Data Source
AI summary
Fluid level sensor systems and methods can include an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space. An inner pressure tube can extend from the inner air space and through the sealed top. A contact sensor can be positioned near the sealed top, the contact sensor including a pair of contacts. A pair of conductors can extend from the contact sensor, one conductor extending from each one of the pair of contacts.