Optical Liquid Sensor Using Roughened Surface Reflection
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Solution Overview
Problem
Existing methods for detecting liquid mist and continuous liquids in pressurized systems, such as natural gas pipelines, are inadequate as they either rely on refractive indices or fluorescence, and can cause issues like corrosion and hydrate formation due to hydrocarbon mist, and fail to meet industry standards when liquids are present.
Innovation Solution
A cone-shaped optical sensor system using a transparent body with a roughened exterior surface that scatters light when dry and becomes reflective when wet, utilizing fiber optic cables to transmit and detect light, allowing for 360-degree liquid detection without exposing working parts to harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If refractive index methods or fluorescence methods are used for liquid detection, then liquid detection capability is provided, but the system complexity increases and reliability decreases in harsh environments
Solution Approach 1:
The patent replaces complex optical systems (refractive index measurement, fluorescence detection) with a simple light reflection principle. A light source shines through a transparent diaphragm, and a photoelectric converter detects changes in light transmission when liquid contacts the diaphragm, eliminating the need for complex measurement systems while improving reliability in harsh environments
Solution Approach 2:
The patent utilizes optical property changes (light transmission vs. light blocking) when liquid contacts the diaphragm. The diaphragm transitions from transparent (gas phase) to opaque (liquid phase), creating a detectable optical signal change that simplifies the detection mechanism while maintaining high reliability
2Reliability
If liquid detection is implemented in pressurized systems, then safety and compliance are improved, but false detections may occur due to environmental factors
Solution Approach 1:
The patent applies local quality by creating a specific detection zone on the diaphragm surface. The roughened outer surface is strategically positioned to contact liquid first, while the inner smooth surface maintains optical clarity. This localized functional differentiation ensures that only liquid contact triggers detection, eliminating false signals from other environmental factors
Solution Approach 2:
The patent introduces a roughened outer surface as an intermediary layer between the process gas/liquid and the diaphragm. This roughened surface acts as a selective interface that allows gas to pass through while blocking liquid, preventing false detections caused by direct liquid contact with the entire diaphragm surface
3Reliability
If continuous monitoring of liquid presence is performed, then pipeline safety is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic action through its passive optical detection mechanism. The light source continuously emits light, and the photoelectric converter continuously monitors light transmission changes. This passive, continuous monitoring requires minimal energy compared to active sampling systems, enabling continuous safety monitoring with low energy consumption
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
Effectively detects liquid mist and continuous liquids in pressurized systems, preventing issues like corrosion and hydrate formation, and ensuring compliance with industry standards by providing a simple and robust method for liquid detection.
Implementation Method 1
When said exterior surface is dry, light projected therethrough is scattered and diffused, due to the surface imperfections formed thereon
Implementation Method 2
When said exterior surface becomes wet, liquid fills the voids in the surface imperfections formed on the exterior surface, rendering said surface reflective, so as to cause light projected therein to be reflected into a second fiber optic cable
Data Source
AI summary
An optical liquid sensor utilizing a light source, fiber optic cables, a light detector and an irregular transparent surface is provided to detect the presence of liquid in mist and continuous form. The sensor may be integrated into a probe designed for insertion into a pressurized fluid process.