Non-Contact Liquid Level Sensing With a Reflective Float
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Solution Overview
Problem
Existing systems for measuring electrolyte volume in redox flow battery systems are prone to human error and mechanical limitations, including accuracy issues with graduated sight gauges and mechanical level sensors, which are also susceptible to degradation and interference from electrolyte turbulence.
Innovation Solution
A non-contact level sensor system is introduced, featuring a float that reflects and/or scatters energy emitted by the sensor, with the float's position within a housing allowing for continuous, accurate monitoring of electrolyte levels without mechanical contact, overcoming transparency and turbulence challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-contact level sensor is used to monitor electrolyte levels, then continuous monitoring capability and resistance to mechanical degradation are improved, but the sensor cannot detect liquid levels when the electrolyte surface is transparent to the emitted energy
Solution Approach 1:
A float is introduced as an intermediary object between the non-contact level sensor and the electrolyte. The float floats on the electrolyte surface and reflects energy back to the sensor, enabling detection when the electrolyte itself is transparent to the emitted energy. This intermediary solves the transparency problem without compromising continuous monitoring capability.
Solution Approach 2:
The float is designed with reflective properties (analogous to color/optical property changes) to ensure it reflects energy back to the sensor. By changing the optical characteristics of the detection target from transparent electrolyte to reflective float, the sensor can continuously detect liquid levels regardless of electrolyte transparency.
2Reliability
If a non-contact level sensor is used to monitor electrolyte levels, then resistance to mechanical degradation and corrosion is improved, but turbulence at the electrolyte surface interferes with accurate detection
Solution Approach 1:
The float acts as a mediator that decouples the sensor from direct exposure to electrolyte turbulence. By detecting the float's position rather than directly measuring the electrolyte surface, the system achieves turbulence-resistant detection while maintaining non-contact operation and resistance to chemical degradation.
3Productivity
If mechanical level sensors are used to measure electrolyte volume, then point measurements can be obtained at greater frequencies, but accuracy is limited by the number of sensors required and they are prone to leaking and degradation
Solution Approach 1:
The mechanical level sensor system is replaced with a non-contact level sensor that uses energy emission and reflection. This substitution eliminates mechanical components that are prone to leaking and degradation from electrolyte exposure, while the float mechanism enables continuous frequency measurements through non-contact detection.
Solution Approach 2:
The float serves as an intermediary that enables the non-contact sensor to achieve measurement frequencies comparable to mechanical sensors. The float's response to electrolyte level changes allows frequent measurements without requiring multiple mechanical sensors, thus improving reliability while maintaining productivity.
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
This solution enables precise and continuous monitoring of electrolyte volumes, reducing human error and mechanical limitations, while maintaining robustness and minimizing maintenance needs.
Implementation Method 1
a float configured to float on a surface of a liquid and reflect and/or scatter energy emitted by the non-contact level sensor
Implementation Method 2
a float configured to float on a surface of a liquid and reflect and/or scatter energy emitted by the non-contact level sensor
Implementation Method 3
a float configured to float on a surface of a liquid
Data Source
AI summary
Systems and methods are provided for a non-contact level sensor system for a liquid tank. The non-contact level sensor system includes a non-contact level sensor positioned above a maximum level of liquid in the liquid tank, a float configured to float on a surface of the liquid and reflect and/or scatter energy emitted by the non-contact level sensor. The position of the float in a plane perpendicular to the energy emitted by the non-contact level sensor is confined within a housing, and the vertical distance between the float and the non-contact level sensor is related to an amount of liquid inside the liquid tank.