Tightly Packed Planar Sensors for Multi-Parameter Sonde Design
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Solution Overview
Problem
Conventional multi-parameter sondes have significant dead space between sensors, leading to increased fluid requirements, longer testing times, biological growth issues, and difficulties in automation and maintenance, which affect sensitivity and reliability.
Innovation Solution
The design features tightly packed, specially shaped sensors that form a continuous sensing surface, minimizing dead space and using a unique interlocking configuration for improved ruggedness and ease of cleaning, with a sensor guard that prevents biological growth and facilitates efficient maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional round or circular sensors are used in multi-parameter sondes, then the sensors can be easily manufactured and installed, but substantial dead space or void volume is created between the sensors
Solution Approach 1:
The patent transitions from conventional circular sensors to sensors with planar (flat) side walls that meet at sharp edges, forming a polygonal cross-section. This geometric change eliminates the curved surfaces that create dead space, allowing sensors to pack tightly together with minimal gaps between adjacent sensors while maintaining ease of manufacture through standard machining processes.
Solution Approach 2:
The sonde is divided into multiple discrete sensor elements with standardized planar geometries that can be independently manufactured and then assembled in a tight-packed configuration. This segmentation allows each sensor to be optimized for its specific measurement function while the overall arrangement minimizes dead space through the planar interfaces between adjacent sensors.
2Ease of repair
If substantial dead space is present between sensors, then sensors can be individually accessed and replaced, but the amount of fluid required during sampling significantly increases
Solution Approach 1:
By using planar sensor surfaces instead of circular geometries, the dead space volume is minimized, directly reducing the amount of fluid required to fill the spaces between sensors during sampling operations.
3Ease of repair
If sensors are spaced apart with dead space, then individual sensor access is easier, but biological growth occurs more readily on and between sensors
Solution Approach 1:
The planar sensor surfaces with sharp edges create a configuration that minimizes crevices and dead spaces where biological growth can initiate and attach. The tight-packed arrangement reduces the total surface area exposed to the environment compared to spaced-apart circular sensors, thereby reducing biological fouling.
4Ease of manufacture
If open spaces exist between sensing surfaces, then sensor installation is simpler, but automation of cleaning becomes difficult and inefficient
Solution Approach 1:
The planar surfaces of the sensors provide flat, accessible areas that are ideal for automated cleaning mechanisms such as wipers or brushes. The tight-packed configuration ensures that cleaning tools can contact all sensor surfaces effectively without navigating around irregular gaps, enabling complete and efficient automated cleaning.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3C
AI summary
Provided are multi-parameter sonde systems having a unique form-factor, wherein the plurality of sensors are arranged in a tight-fit configuration. This provides a single distal sensing surface and minimal separation distance between adjacent sensors. The sensors may be pie shaped with an interlocking feature to tightly hold the sensors together, with a sensor guard disposed over the outer surface of the interlocked sensors. Sensor-guards disclosed herein may have an integrated sensor storage and sensor guard configuration, thereby avoiding a need for a separate storage cup and that are configured to minimize unwanted biological growth. Also provided are uniquely shaped individual sensors having interlocking features to hold several sensors together in a sonde.