Liquid Level Sensor with Float and Reed Switches for Multi-Level Detection
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Solution Overview
Problem
Existing liquid level sensors face challenges in detecting multiple liquid levels accurately and reliably without increasing costs or reducing storage capacity, and they are prone to malfunctions that can result in incorrect signal output.
Innovation Solution
A liquid level sensor design featuring a sleeve with a float that moves along it, a resistor string with grounded junction points corresponding to specific liquid levels, and separate signal output and warning signal mechanisms to ensure accurate and reliable detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple liquid level sensors are disposed in a tank to detect different liquid levels, then the number of detectable liquid levels increases, but the installation cost and device complexity increase
Solution Approach 1:
The patent combines multiple liquid level detection functions into a single sensor device. The sensor integrates a float mechanism with multiple reed switches arranged at different heights, allowing one device to detect multiple liquid levels simultaneously. This merging approach eliminates the need for multiple separate sensors, reducing installation cost and device complexity while maintaining the capability to detect multiple liquid levels.
Solution Approach 2:
The single liquid level sensor is designed to perform multiple detection functions by incorporating reed switches at different positions along the sleeve. The float mechanism universally triggers appropriate reed switches based on liquid level height, enabling one device to detect multiple discrete liquid levels (upper limit, intermediate, lower limit positions) that would otherwise require multiple specialized sensors.
2Reliability
If a liquid level sensor uses a float and reed switch mechanism to detect liquid levels, then the detection reliability improves, but the device complexity and cost increase
Solution Approach 1:
The liquid level sensor employs a passive detection mechanism where the float automatically moves with liquid level changes and triggers reed switches through magnetic field interaction without requiring external power or complex control circuits. The reed switches self-activate when the magnetized float approaches, providing reliable detection through a simple, maintenance-free mechanism that reduces overall device complexity.
3Measurement precision
If the resistor string and grounding means are used to generate liquid level signals, then the signal accuracy improves, but the susceptibility to malfunction and incorrect signal output increases
Solution Approach 1:
The liquid level sensor incorporates a warning signal mechanism that provides feedback when the float approaches predetermined warning positions. This feedback system monitors the liquid level and triggers warnings before critical levels are reached, allowing the system to detect and respond to abnormal conditions. The feedback mechanism helps prevent incorrect signal output by alerting operators to potential malfunctions or unusual liquid level patterns.
Solution Approach 2:
The sensor includes predetermined warning positions and warning signals that activate before the liquid reaches critical levels or when malfunctions are detected. This beforehand cushioning approach allows the system to prepare for potential issues by providing advance warning, reducing the likelihood of incorrect signal output and improving overall reliability through preventive monitoring.
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 design allows for accurate detection of liquid levels with high reliability, enabling effective management of liquid levels in tanks without reducing storage capacity and minimizing the risk of incorrect signal output.
Implementation Method 1
a float configured so as to move along said sleeve according to fluctuation of liquid level
Implementation Method 2
a plurality of grounding means disposed inside said sleeve respectively corresponding to junction parts between adjacent resistors included in said resistors in said resistor string, and configured such that said junction part is grounded when said float is located within a predetermined distance from the corresponding junction part
Data Source
AI summary
A liquid level sensor 1 comprises a sleeve 2 disposed so as to extend in the vertical direction, a float 3 configured so as to move along said sleeve according to fluctuation of liquid level, a resistor string 4, a plurality of grounding means 5 disposed inside the sleeve 2 and a liquid level signal output means 6 to take out an electric signal detected between a positive electrode side end part 4a and a junction part grounded by the grounding means 5 as a liquid level signal that is a signal corresponding to the liquid level, and further comprises a warning signal output means 7 to output a warning signal when the float 3 is located within a predetermined distance from a warning position that is a predetermined position within a movable range of the float 3. Thereby, a compact and reliable liquid level sensor is realized.