Spring-Loaded Sensor Seal With Wiping Lip for Debris-Free Level Sensing
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Solution Overview
Problem
Existing fluid level sensor assemblies face challenges in ensuring accurate sensing and control of valves due to disruption and contamination of sensors by fluid flow, particularly in ensuring correct positioning and orientation to avoid water traps and debris accumulation, which can lead to inaccurate readings and sensor damage.
Innovation Solution
A seal assembly comprising a seal body with a spring and two lips, where the thinner lip provides a seal and the thicker lip wipes debris off the sensor, supported by a gasket and potentially aided by a motor, allowing the seal to move along the sensor and be mounted in various orientations without creating a water trap, with hard stops limiting movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is located in the pipes through which the fluid flows, then the sensor can detect fluid level, but the sensor disrupts fluid flow and becomes contaminated by particles and debris
Solution Approach 1:
The seal assembly acts as an intermediary between the sensor and the fluid flow environment. It provides a protective interface that allows the sensor to detect fluid levels while preventing direct contact between the sensor and contaminated fluid, thus resolving the contradiction between measurement capability and contamination risk
2Measurement precision
If the sensor is positioned to avoid water traps, then accurate sensing is improved, but the positioning and location become more complex and challenging
Solution Approach 1:
The seal assembly is designed to be orientation-independent and can be mounted in any position without creating water traps. This universal mounting capability simplifies installation while maintaining sensing accuracy, resolving the contradiction between measurement precision and positioning complexity
3Object-affected harmful factors
If a seal is provided around the sensor, then contamination is prevented, but the seal structure becomes more complex
Solution Approach 1:
The seal utilizes flexible lips made of elastomeric material that can deform to conform to the sensor surface. This flexible membrane approach provides effective sealing and contamination protection while maintaining a relatively simple structure, resolving the contradiction between protection and complexity
4Device complexity
If the seal is made stationary, then the structure is simpler, but the seal cannot effectively remove debris from the sensor surface
Solution Approach 1:
The seal incorporates a movable wiping lip that can dynamically move along the sensor surface to remove debris. This dynamic element is actuated by fluid pressure differential across the seal, providing automated cleaning functionality while maintaining relatively simple structure, resolving the contradiction between simplicity and effectiveness
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 seal assembly ensures accurate and reliable fluid level sensing by preventing contamination and debris accumulation, allowing the sensor to be mounted in any orientation without water traps, reducing the risk of false readings and sensor damage, while also facilitating easy assembly and cost-effectiveness through additive manufacturing.
Implementation Method 1
The spring preferably moves the seal body in response to a fluid pressure acting on the first lip
Implementation Method 2
a spring mounted to the seal and arranged to move the seal body along the sensor
Data Source
Figure 1~2
Figure 3
Figure 4(a)~5
AI summary
A seal for a fluid level sensor assembly mounted in a pipe, the seal (100) comprising a seal body (101) arranged to be sealingly fitted around a sensor (2), the seal body having a first side defining a first lip (102) and a second side defining a second lip (103), the second lip being thinner than the first lip, and a spring (6) mounted to the seal and arranged to move the seal body along the sensor, when mounted around the sensor, such that the second lip provides a seal around the sensor and the first lip wipes the sensor to remove debris thereon.