Magnetic Fluid Level Sensor with External Magnetometers
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Solution Overview
Problem
Conventional fluid level sensors for fuel tanks face challenges due to the incorporation of electrical components and power supply within the container, which increases complexity, cost, and risk of ignition, especially when dealing with corrosive or flammable fluids.
Innovation Solution
A magnetic field-based fluid level sensor system that uses a magnetic element floating within the fluid, with external magnetic field sensors to determine its position, eliminating the need for electrical components inside the container and simplifying installation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components and power supply are incorporated within the container, then fluid level sensing capability is achieved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the electrical sensing components from the container interior and relocates them to the exterior. The float mechanism remains inside to track fluid level, but the magnetic field sensors are positioned outside the container wall, eliminating the need for sealed electrical compartments and complex wiring within the tank.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the internal float mechanism and external sensors. The float contains magnetic elements that generate a magnetic field detectable by external sensors, allowing non-contact measurement of fluid level without requiring electrical components inside the container.
2Reliability
If electrical components are sealed from corrosive fluid, then reliability is maintained, but manufacturing cost and complexity increase
Solution Approach 1:
The patent removes all electrical sensing components from the container interior, eliminating the need for corrosion-resistant sealing structures. The float mechanism uses only magnetic elements and buoyant materials that are inherently resistant to corrosion, while external sensors remain completely isolated from the fluid environment.
3Reliability
If power supply is provided to internal sensors, then sensing function operates, but ignition risk of flammable vapor increases
Solution Approach 1:
The patent extracts all power consumption elements from the container interior. The float mechanism uses passive magnetic elements that require no power supply, and external sensors are powered separately outside the container, completely eliminating electrical ignition sources within the flammable vapor environment.
Solution Approach 2:
The patent converts the constraint of不能使用 electrical components inside the container into a benefit by using passive magnetic field interaction. The magnetic field penetrates the container wall without requiring breaks or penetrations, providing safe, contactless measurement that inherently avoids ignition risks while maintaining sensing functionality.
4Measurement precision
If mechanical float arm and electrical sensor are used, then angular position can be sensed, but installation complexity increases
Solution Approach 1:
The patent removes the electrical sensor from the container interior and relocates it externally. The float arm with magnetic elements remains inside to track fluid level, but the magnetic field sensor is positioned outside the container wall, simplifying installation by eliminating the need for sealed electrical compartments and complex wiring within the tank.
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 allows for accurate fluid level detection without internal electrical components, reducing complexity and risk, and can operate in various fluid types and container shapes, including those with narrow passages, while avoiding ignition hazards.
Implementation Method 1
a magnetic element having a flotation device that suspends the magnetic element in the fluid held by the reservoir, so that the magnetic element randomly floats in proximity to a top of the fluid surface
Implementation Method 2
Two or more magnetic field sensors, optionally magnetometers, are associated with the reservoir in at least two different locations, spaced apart from one another. The magnetic field sensors may sense the strength of the magnetic field around the magnetic element to generate signals that are sent to the processor
Data Source
AI summary
A fluid sensor system capable of sensing a fluid level or a volume of fluid held by a reservoir, such as a container or a tank. In one embodiment, the system may include a magnetic element in a flotation device that suspends the magnetic element in the fluid held by the reservoir, so that the magnetic element randomly floats in proximity to a top of the fluid surface. Two or more magnetic field sensors or magnetometers are associated with the reservoir in at least two different locations, spaced apart from one another. The system further includes a processor coupled to the sensors. The magnetic field sensors may sense the strength of the magnetic field around the magnetic element to generate signals that are sent to the processor. The processor may then determine the location of the magnetic element within the reservoir based on the signals. The determined location can be correlated to a volume of fluid within the tank which is output to another device and/or a user.