Solid State Pump Control Using Ultrasonic Level Sensing
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Solution Overview
Problem
Existing pump control systems rely on electromechanical components, which are unreliable and increase manufacturing costs and complexity, necessitating a more reliable solution without substantial cost or complexity increases.
Innovation Solution
The implementation of solid state circuitry for liquid level management and motor power switching using sonic/ultrasonic wave conduction for level detection and semiconductor power switching devices like IGBTs and MOSFETs to control pump motors, reducing interference and dissipative losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromechanical components are used for switching and level sensing, then the system can be manufactured with conventional components, but the reliability of the system deteriorates
Solution Approach 1:
The patent replaces electromechanical float switches and mechanical relays with solid-state electronic components including ultrasonic sensors for level detection and TRIACs for motor control. This substitution eliminates moving parts and mechanical wear, thereby improving reliability while maintaining manageable system complexity through standardized electronic circuits
Solution Approach 2:
The patent uses ultrasonic sensors to create an electronic copy or representation of the liquid level position without physical contact. The ultrasonic waves bounce off the liquid surface and return to the sensor, providing a non-contact method to sense level that avoids the reliability issues of mechanical float switches
2Ease of manufacture
If electromechanical components are used for switching, then the system structure is simpler, but the manufacturing cost increases
Solution Approach 1:
The patent replaces electromechanical float switches and mechanical relays with solid-state electronic components including ultrasonic sensors for level detection and TRIACs for motor control. This substitution eliminates moving parts and mechanical wear, thereby improving reliability while maintaining manageable system complexity through standardized electronic circuits
3Loss of energy
If conventional switching devices are used for motor control, then the circuit design is simpler, but power losses increase due to dissipative effects
Solution Approach 1:
The patent replaces conventional mechanical switches and resistive control devices with solid-state TRIACs for motor control. TRIACs provide efficient power switching with lower on-state voltage drops and reduced dissipative losses compared to mechanical contacts and resistive dividers, thereby reducing energy loss while accepting increased circuit complexity
Solution Approach 2:
The patent changes the electrical parameters of the switching device by using TRIACs with lower on-resistance and faster switching characteristics compared to conventional switches. This parameter change reduces the voltage drop across the switching device during conduction, thereby reducing I²R losses and improving overall system efficiency
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 solution provides superior reliability and reduced power consumption with minimal dissipative losses, eliminating the need for mechanical switches and snubbers, while maintaining low interconnect losses and ease of assembly.
Implementation Method 1
Level detection can be accomplished by detecting the strength of sonic/ultrasonic wave conduction between a sonic/ultrasonic transmitter(s) and a separately located sonic/ultrasonic receiver(s)
Implementation Method 2
A method in accordance with the invention detects the density differential between air and a liquid (water)
Data Source
AI summary
A pump control system incorporates one or more solid state level sensors as well as solid state pump control switches. Elimination of mechanical or electrode-mechanical parts by using ultrasonically based fluid level sensors as well as solid state switches for motor control enhances reliability and results in reduced power consumption and dissipation.