Composite Optical Lens for Continuous Liquid Level Sensing
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Solution Overview
Problem
Existing level sensors for liquids in containers, particularly removable ones, face inaccuracies when the liquid level is low and are not adaptable for continuous measurement without using floats or requiring dismantlable electric connections.
Innovation Solution
An optical level sensor system comprising a photo emitting and receiving element paired with a composite lens, where the lens consists of two concentric cylindrical bodies with a reflecting coating, allowing liquid level measurement without mechanical connections, enabling use in both fixed and removable containers without disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a float with photo emitting and receiving elements is used to detect liquid level, then the liquid level can be detected, but the measurement is inaccurate when the liquid level is low and approaches the size of the float dimensions
Solution Approach 1:
The patent replaces the mechanical float-based detection system with an optical measurement system. Instead of using a physical float that moves with the liquid level, the invention uses a photo emitting element and photo receiving element that remain stationary while measuring light transmission through the liquid column. This substitution eliminates the measurement inaccuracy that occurs when the liquid level approaches the float dimensions, as the optical system can accurately measure even very low liquid levels without requiring a moving mechanical component.
2Measurement precision
If a magnetic field sensitive switch with float is used for level detection, then the device can detect maximum or minimum liquid level, but it cannot carry out continuous level measurement
Solution Approach 1:
The patent replaces the magnetic field sensitive switch and float mechanism with a direct optical transmission system. The photo emitting element emits light through the container wall and liquid column directly to the photo receiving element, eliminating the need for mechanical floats and magnetic switches. This allows continuous measurement of liquid level by continuously monitoring light transmission intensity, providing both continuous measurement capability and simplified device structure.
3Adaptability or versatility
If dismantlable electric connections are used to adapt level sensor to removable containers, then the sensor can be used with removable containers, but the device complexity increases and reliability decreases
Solution Approach 1:
The patent replaces electrical connections with optical connections. The photo emitting element and photo receiving element are positioned on opposite sides of the container wall, measuring liquid level through non-contact optical transmission. This eliminates all electrical connections between the sensor and the removable container, allowing the container to be freely removed and reinstalled without any disconnection operations, thereby maintaining both high adaptability and high reliability.
4Measurement precision
If an optical sensor system is implemented for removable containers, then continuous and accurate liquid level measurement is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the photo emitting element and photo receiving element into a single integrated sensor unit that can be mounted on the appliance housing. The optical measurement path passes through the container wall and liquid column, combining the light source, detection path, and sensor into a unified system. This integration approach achieves accurate continuous liquid level measurement while minimizing device complexity by eliminating separate mechanical components and electrical connections.
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
The system provides accurate, continuous liquid level measurement in both fixed and removable containers, ensuring reliability and cost-effectiveness, with the ability to maintain functionality without electric disconnections during container removal and reinsertion.
Implementation Method 1
a photo emitting element (8) and a photo receiving element (9) carried side-by-side by a supporting and feeding element (10)
Implementation Method 2
the side wall of the second cylindrical body is made so as to be at least partially reflecting towards the side wall of the first cylindrical body
Implementation Method 3
an attenuation of a radiation emitted by the photo emitting element and detected by the photo receiving element is proportional to the level of liquid between the side walls of the first and second bodies, as the emitted radiation is reflected and refracted between the side walls of the two cylindrical bodies and the liquid present therebetween
Implementation Method 4
detecting the attenuation of such a radiation emitted by the photo emitting element and reflected and refracted as mentioned above
Data Source
AI summary
An optical sensor including a photo emitting element and a photo receiving element carried side-by-side by a supporting and feeding element either associated or associable in use with a support for a container, and a composite lens, either associated or associable with the container, designed so as to remain in use immersed in a liquid contained in the container and facing the photo emitting and photo receiving elements; the lens including: a first cylindrical body made of a light-permeable material, mountable in use vertically from the top of the container facing the photo emitting and photo receiving elements to a bottom wall of the container; and a second cylindrical body, arranged concentrically with and outside the first body and open towards the bottom wall; respective side walls of the first and second cylindrical bodies having the same length, that of the second body being separated from that of the first body by a predetermined annular clearance, and being made so as to be at least partially reflecting towards the first cylindrical body.