Rotary Position Sensor for Water Treatment Valve Control
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Solution Overview
Problem
Existing water softening systems face inefficiencies in accurately determining the rotational position of components, leading to recalibration requirements and increased operational time, especially after memory loss events, due to inaccurate detection methods and variable rotation speeds.
Innovation Solution
A water treatment system incorporating a rotary position sensor with a resistive material and contact wiper, which applies an electric current to measure electrical resistance to detect the rotational position of a rotatable element, allowing direct movement between positions without recalibration, using computer-executable instructions to control the rotation and position detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two slots and switches are used to control the flow of water, then the system can detect home and regeneration positions, but the system requires recalibration after memory loss events and inefficient movement of the cam
Solution Approach 1:
The patent replaces the mechanical switch-based position detection system with an optical sensor and rotary disc system. The optical sensor detects the position of the rotary disc more reliably, and the system stores the detected position in memory to avoid recalibration after power loss, thus resolving the contradiction between reliable position detection and recalibration time
Solution Approach 2:
The patent creates a digital copy of the mechanical position information by using an optical sensor to detect the rotary disc position and storing it in memory. This digital representation allows the system to recall the position after memory loss events without requiring physical recalibration, reducing recalibration time while maintaining detection reliability
2Extent of automation
If a rotating cam with cylindrical features is used to engage mechanical switches, then digital codes for positions can be generated, but the positions are not accurate and recalibration is required after memory loss
Solution Approach 1:
The patent replaces the mechanical cam and switch system with an optical sensing system that uses a rotary disc with radial features. The optical sensor detects the presence or absence of light through these features to generate position codes, providing both automatic identification and higher measurement precision without requiring recalibration
3Measurement precision
If rotary discs with uniformly placed slots and optical sensors are used, then home position can be indicated, but the system requires recalibration every time components change orientations and rotation speed variations cause detection errors
Solution Approach 1:
The patent performs preliminary action by storing the detected home position and component orientations in memory before any regeneration cycle begins. When components need to change orientations, the system retrieves the stored position information rather than requiring recalibration, thus eliminating the time loss associated with repeated recalibration while maintaining accurate home position detection
Solution Approach 2:
The patent creates a digital copy of the mechanical position and orientation information in memory, allowing the system to recall and use this information across multiple regeneration cycles without recalibration. This digital copying resolves the contradiction by maintaining detection accuracy while eliminating the time penalty of repeated recalibration
4Adaptability or versatility
If DC motor is used to rotate the disc, then the system can change positions, but variable rotation speed causes improper detection or misinterpretation of slots
Solution Approach 1:
The patent implements feedback by continuously monitoring the rotary disc position using the optical sensor and comparing it against expected positions. The system can detect when the disc has reached the correct position regardless of rotation speed variations, and can adjust or repeat detection if needed, thus maintaining slot detection accuracy while preserving position flexibility through the DC motor
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 precise detection of rotational positions without recalibration, reducing operational inefficiencies and allowing direct rotation between positions, thereby improving the accuracy and speed of water treatment processes.
Implementation Method 1
the rotary position sensor comprises a resistive material having an electrical resistance when an electric current is applied, and the resistive material comprises a first end and a second end
Data Source
AI summary
Water treatment and valve control systems and apparatuses, and methods of using the same, are disclosed. In some examples, the apparatuses, systems, and methods include use of a rotary position sensor and one or more rotatable elements configured to, when moving from an initial rotational position to subsequent rotational positions, move one or more element of a valve assembly. In various examples of the apparatuses, systems, and methods, the rotatable element rotates directly from one rotational position to another rotational position. In certain examples, the rotary position sensor measures an electrical resistance value to detect the rotational position of the rotatable element.