Modular position and state sensing system and method
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Solution Overview
Problem
Existing position sensors for filter pans in controlled cooking systems are prone to damage, misalignment, and difficulty in detecting fluid status, leading to issues like spillage and leakage.
Innovation Solution
A multipurpose sensing module with a capacitive sensor and connector system is integrated into the filter pan to detect proper positioning and fluid status, using capacitive sensing to communicate with a controller for interlock systems to enable or disable fluid pumping and heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sensor pads or micro-switches are used to detect filter pan position, then the filter pan presence can be detected, but the sensors become dirty, damaged, or misaligned and are difficult to clean, repair, or replace
Solution Approach 1:
The patent replaces mechanical contact sensors (micro-switches and contact pads) with a capacitive sensor that detects filter pan position through non-contact electrical fields. This eliminates mechanical wear, contamination issues, and alignment problems while maintaining reliable detection capability. The capacitive sensor can detect the dielectric properties of the filter pan material without physical contact, solving the maintenance difficulty problem.
Solution Approach 2:
The patent introduces a capacitive sensing field as an intermediary between the sensor and the filter pan. Instead of direct mechanical or electrical contact, the capacitive field acts as a mediator that can detect the presence and position of the filter pan through its dielectric properties, eliminating the need for physical contact points that can become dirty or damaged.
2Ease of operation
If micro-switches are positioned at the rear of the filter pan cavity, then they can detect filter pan presence, but they are subject to difficult operating conditions that cause them to break and mis-detect
Solution Approach 1:
The patent replaces the mechanically actuated micro-switch with a capacitive sensor that operates through electrical fields rather than mechanical contact. This substitution eliminates the reliability issues caused by difficult operating conditions such as contamination, moisture, and physical stress that affect micro-switches positioned in the rear cavity.
Solution Approach 2:
The capacitive sensor automatically adapts to the operating environment by detecting changes in dielectric constants and capacitance values. It self-adjusts to different filter pan materials and positions without requiring manual calibration or protection mechanisms, maintaining reliability under varying operating conditions.
3Adaptability or versatility
If micro-switches are used to detect filter pan position, then basic presence detection is achieved, but they cannot detect fluid status such as whether the filter pan is full or empty
Solution Approach 1:
The capacitive sensor serves multiple functions: it detects filter pan presence, determines filter pan position (aligned or misaligned), and monitors fluid status (full or empty). By measuring capacitance changes caused by different dielectric materials (filter pan material vs. fluid), a single sensor provides comprehensive system monitoring that replaces multiple specialized sensors.
Solution Approach 2:
The patent utilizes changes in capacitance parameters to detect different states. The capacitive sensor measures different capacitance values when the filter pan is present versus absent, when properly aligned versus misaligned, and when full versus empty of fluid. These parameter changes provide rich information about system state without requiring multiple sensors.
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
Ensures reliable detection of filter pan presence and fluid status, preventing spillage and leakage by enabling precise control of fluid pumping and heating systems.
Implementation Method 1
The sensor is configured and disposed to determine the capacitance and presence of a cooking fluid within the removable filter pan
Data Source
AI summary
A multipurpose sensing module used in association with a removable filter pan includes a capacitive sensor that is disposed within or proximate to the removable filter pan such that the sensor is adapted to measure and determine status parameters and data of a fluid contained within the removable filter pan. A sealed control box is adapted to house sensor electronics that are in communication with the sensor. The sensor electronics are adapted to receive the status parameters and data from the capacitive sensor. A connector is adapted to allow the sensor electronics to communicate with a controller of the controlled system. The controller is adapted to determine a presence and status of the removable filter pan based on the communication between the sensor electronics and the controller.