Magnetic Lubrication Level Sensor for High Viscosity Fluids
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Solution Overview
Problem
Existing machine lubrication systems face challenges in monitoring lubricant levels due to the high viscosity of lubricants, which causes traditional level sensors to malfunction and requires manual visual indicators that are not practical for continuous monitoring, especially during machine operation or refill operations, leading to potential overfilling and contamination.
Innovation Solution
A machine lubrication system with a follower that moves within the reservoir and activates magnetically actuated switches, providing continuous level monitoring through a first level sensor connected to an operator station and a second level sensor connected to a remote indicator, allowing for real-time lubricant level indication and preventing overfilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional float-type level sensors are used, then the sensor can provide level indication, but the high viscosity lubricant renders the float immobile and inoperative
Solution Approach 1:
The patent replaces the mechanical float-type level sensor with a magnetic field-based sensor system. A magnet is attached to the follower plate, and magnetic reed switches are positioned along the reservoir to detect the follower's position without mechanical contact. This eliminates the problem of high viscosity lubricant immobilizing mechanical floating components while maintaining reliable level detection capability.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the follower plate and the level detection system. The magnet attached to the follower plate generates a magnetic field that actuates reed switches at different heights, allowing level detection through magnetic interaction rather than direct mechanical contact with the viscous lubricant.
2Loss of information
If a visual indicator is used, then the operator can see the lubricant level, but the operator must be able to physically see the indicator which is not practical during machine operation
Solution Approach 1:
The patent implements a feedback system where the magnetic reed switches detect the follower plate position and send electrical signals to indicators in the operator's station. This allows continuous level monitoring information to be fed back to the operator electronically, eliminating the need for direct visual observation of a physical indicator and enabling monitoring during machine operation.
Solution Approach 2:
The patent replaces the mechanical visual indicator system with an electrical signaling system. The magnetic reed switches generate electrical signals that are transmitted to digital or visual indicators in the operator's station, converting direct mechanical indication into remote electrical feedback that can be accessed during operation.
3Device complexity
If no level monitoring is provided, then the system is simpler, but the tank can be over-filled causing lubricant to be expelled onto the machine and into the environment
Solution Approach 1:
The patent uses the magnetic level sensor system to provide feedback on reservoir fill level. When the follower plate reaches a predetermined height, the magnetic reed switches detect this position and send signals to prevent further filling or to alert the operator, thereby preventing overfilling and lubricant expulsion without requiring a complex monitoring system.
Solution Approach 2:
The patent implements preliminary detection of the maximum fill level using the magnetic sensor system. Before overfilling can occur, the sensor detects when the follower plate reaches the safe level and triggers an alert or prevents further filling, taking preliminary action to avoid the harmful effect of lubricant expulsion.
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
Enables continuous and remote monitoring of lubricant levels, preventing premature wear, damage, and environmental contamination by ensuring accurate lubricant supply and refill operations, even when the machine is in operation or being serviced.
Implementation Method 1
A magnet is connected to the follower and positioned such that movement of the follower within the reservoir cavity along the axis will actuate at least one of the switches
Data Source
AI summary
A machine lubrication system that includes an assembly for sensing the level of lubricant in the reservoir, the reservoir including a follower that travels axially within the reservoir and substantially conforms to an inner cross-sectional dimension thereof, a magnet being attached to the follower for actuation of a plurality of magnetically actuated switches. The system may include a first and second level sensor, which may be independently connected to one or more power sources, where the first level sensor may be associated with an operator station, and the second level sensor may be associated with a remote indicator.