Liquid Level Sensor Insulating Region Over Probe Foot
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid level sensors installed at the bottom of tanks face challenges with contaminant accumulation and inaccurate readings due to droplets on the probe foot, which can lead to energy induction issues and difficulty in cleaning.
Innovation Solution
A liquid level sensor design featuring an inner and outer capacitor tube with an insulating minimum distance between the inner capacitor tube base and the probe foot, preventing droplets from contacting the inner capacitor tube and ensuring accurate capacitance measurements by maintaining a separate insulating region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the capacitor tubes are positioned directly on the probe foot, then the sensor structure is simplified and electronic components can be easily mounted, but contaminants accumulate in the trapping area and droplets affect capacitance measurements
Solution Approach 1:
The sensor structure is divided into distinct functional zones: a probe foot region for mounting electronic components and a capacitor region elevated above it. The capacitor tubes are positioned on an insulating support structure rather than directly on the probe foot, creating spatial separation between the mounting base and the measurement zone. This segmentation prevents contaminant accumulation in the measurement area while maintaining ease of assembly.
Solution Approach 2:
An insulating support structure acts as an intermediary element between the probe foot and the capacitor tubes. This intermediary component serves multiple functions: it elevates the capacitor tubes to prevent droplet contact, provides a mounting surface for electronic components, and maintains electrical isolation. The intermediary structure resolves the contradiction by enabling both easy assembly and precise measurement.
2Ease of operation
If the probe foot is in direct contact with the capacitor region, then electronic components can be mounted within the probe foot, but water droplets on the probe foot cause capacitance variations and inaccurate readings
Solution Approach 1:
The solution moves the capacitor tubes from the horizontal plane of the probe foot to a vertical elevation above it. By introducing a vertical dimension through the insulating support structure, the capacitor region is positioned in a different spatial dimension where it is not affected by droplets on the probe foot surface. This dimensional separation maintains ease of component mounting while ensuring measurement reliability.
Solution Approach 2:
The capacitor tubes are extracted from direct contact with the probe foot and positioned in a separate elevated zone. This extraction removes the harmful interaction between probe foot contaminants and the capacitance measurement zone, while the insulating support structure provides the necessary mounting functionality for electronic components.
3Volume of moving object
If the capacitor region starts immediately over the probe foot, then the sensor structure is compact, but contaminants are trapped and difficult to evacuate requiring disassembly
Solution Approach 1:
The sensor is segmented into a lower probe foot zone for mounting and an upper capacitor zone for measurement. This vertical segmentation creates a clear separation between the contaminant-prone mounting area and the clean measurement area, allowing contaminants to be evacuated from the probe foot region without affecting the capacitor region and without requiring disassembly.
Solution Approach 2:
By elevating the capacitor region to a different vertical dimension above the probe foot, the design creates a compact vertical profile while preventing horizontal contaminant trapping. The insulating support structure enables this vertical arrangement, achieving both compactness and ease of maintenance.
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 effectively prevents contaminants from affecting the sensor's accuracy and allows for easy cleaning, while protecting electronic components from liquid exposure, thereby providing reliable and precise liquid level measurements.
Implementation Method 1
the liquid level within a tank is measured as a function of the capacitance between a pair of tubes when the liquid is within the region defined by the tubes
Implementation Method 2
a capacitor region arranged to hold a liquid is defined between the outer capacitor tube and the inner capacitor tube
Data Source
AI summary
A liquid level sensor comprising an inner capacitor tube, an outer capacitor tube and a probe foot suitable for placing the liquid level sensor on a bottom surface of a liquid tank, wherein a capacitor region arranged to hold a liquid is defined between the outer capacitor tube and the inner capacitor tube, and wherein an insulating minimum distance is left between the inner capacitor tube base and the probe foot, the insulating minimum distance being sufficient to prevent a droplet of water on the probe foot from making contact with the inner capacitor tube.