Sealed Barrier Chamber Float Sensor for Fluid Level Measurement
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Solution Overview
Problem
Current electronic fluid level sensing technologies, particularly analog sensors, are complex and expensive due to the need for advanced electronics and chemical/electrical isolation, which increases costs and complexity.
Innovation Solution
A float-based system with a magnetically coupled target and sensor, where the float and target move within a sealed barrier chamber, using energy sources like light, audio, or RF to detect fluid level changes, providing a low-cost and accurate measurement method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electronic sensors (capacitive or ultrasonic) are used for analog fluid level measurement, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex electronic sensing systems (capacitive or ultrasonic sensors) with a simple optical detection system. A float with a reflective target moves mechanically with fluid level changes, and a basic optical sensor detects the reflected light to determine level position. This substitution of mechanical-optical for electronic systems reduces complexity while maintaining measurement precision.
Solution Approach 2:
The patent uses an optical copy/reflection approach where a light source illuminates a reflective target attached to the float, and the optical sensor detects the reflected light pattern. This optical copying method provides accurate position information without requiring complex electronic sensors, thereby reducing device complexity while preserving measurement precision.
2Measurement precision
If electronic sensors are used for analog fluid level measurement, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive electronic sensors with inexpensive optical components. The float mechanism with reflective target and basic optical sensor assembly uses readily available, low-cost parts that are simpler to manufacture and assemble than capacitive or ultrasonic electronic sensors, thereby reducing manufacturing cost while maintaining measurement precision.
Solution Approach 2:
The patent employs simple, inexpensive optical components that can be easily manufactured and replaced if needed. The optical sensor system with light source and detector uses basic components with lower material and manufacturing costs compared to electronic sensors, making the overall system more cost-effective for fluid level measurement applications.
3Reliability
If electronics are chemically and electrically isolated from the fluid, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the sensing mechanism from direct contact with the fluid by using a float that moves on the fluid surface while the optical sensor and light source remain in air within a sealed housing. This extraction eliminates the need for complex chemical and electrical isolation barriers, reducing device complexity while maintaining reliability through physical separation of electronics from the fluid environment.
Solution Approach 2:
The patent introduces air as an intermediary medium between the fluid and the electronic/optical components. The sealed housing creates an air-filled barrier that naturally prevents chemical and electrical contact between the fluid and sensitive components, providing reliable isolation without requiring additional isolation mechanisms or complex sealing systems.
4Measurement precision
If float and target are exposed to fluid, then measurement precision is improved, but reliability decreases due to degradation
Solution Approach 1:
The patent extracts the optical sensor and light source from the fluid environment by housing them in a sealed enclosure that remains above the fluid level. The float with its reflective target is the only component exposed to fluid, while the sensitive optical components are protected in air, maintaining both measurement precision through optical detection and reliability through component protection from fluid degradation.
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
This approach offers a cost-effective and accurate method for fluid level measurement, reducing complexity and costs by using a sealed barrier chamber to protect electronics and employing simple energy sources for detection, suitable for various industrial applications.
Implementation Method 1
a float that floats at or near the top surface of a fluid... When the fluid raises or lowers, the float will follow and will be similarly raised or lowered
Implementation Method 2
The target is magnetically coupled to the float so that when the float raises or lowers with the height of the fluid, the target also raises or lowers
Implementation Method 3
The sensor is capable of detecting energy reflected from the target so that the amount of energy ultimately corresponds to the height of the fluid
Data Source
AI summary
Embodiments of a system and method for providing a float-based sensor are disclosed. Embodiments of the system and method provide a sealed pipe or tube, also referred to as a barrier chamber, that is located inside a tank (or body of water) to measure a fluid level in the tank, such as a fuel tank, an oil tank, a chemical tank, a water tank, and the like. No fluid is able to penetrate the interior of the sealed pipe to avoid any electrical, mechanical, or chemical problems, or degradation. Embodiments of the system and method use a float having a magnet that magnetically couples to a target located within the barrier chamber's interior. The movement of the target is constrained to one dimension, allowing it to move up and down as the fluid level in the tank (or body of water) moves the magnetically coupled float up and down.