Ultrasonic Sprayer Optical Liquid Level Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional sprayer technologies fail to accurately detect low liquid levels due to bubbles covering the mesh, leading to incorrect conductivity readings and potential damage to the ultrasonic resonator.
Innovation Solution
A removable detection unit with a light source and optical sensor is used to measure the intensity of the gas emitted by the sprayer, allowing for precise determination of liquid levels and powering off the resonator when the gas density falls below a threshold, preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrodes are used to detect liquid level by measuring conductivity, then the detection is simple, but bubbles covering the mesh cause false positive readings leading to unreliable detection
Solution Approach 1:
The patent replaces the electrical conductivity-based detection system with an optical detection system. A light source emits light through a transparent window to illuminate the gas, and an optical sensor detects the reflected light intensity. This optical measurement is not affected by bubbles on the mesh, eliminating false positive readings while maintaining simple system architecture.
Solution Approach 2:
The patent introduces light as an intermediary medium to detect liquid level. Instead of directly measuring conductivity through the mesh (which is blocked by bubbles), the system uses light transmission through the gas and window as an intermediary measurement that indirectly indicates liquid level without being affected by bubble presence.
2Productivity
If the resonator continues to operate when liquid level is low, then productivity is maintained, but the resonator is damaged due to insufficient liquid
Solution Approach 1:
The patent implements preliminary detection of liquid level using the optical sensor before the resonator operates. When the optical sensor detects that light intensity is below the threshold (indicating low liquid level), the system powers off the resonator in advance. This preliminary action prevents the resonator from operating under damaging conditions, ensuring reliability while maintaining productivity through timely intervention.
Solution Approach 2:
The patent establishes a feedback loop where the optical sensor continuously monitors liquid level and provides feedback to the control system. Based on this feedback, the resonator is powered on or off accordingly. This closed-loop feedback mechanism ensures the resonator only operates when liquid is sufficient, protecting durability while maintaining operational productivity.
3Device complexity
If a fixed detection unit is used, then the structure is simple, but the design lacks flexibility for different applications
Solution Approach 1:
The patent divides the detection system into a separate, removable detection unit that can be independently attached or detached from the sprayer. This segmentation allows the detection unit to be designed with simple internal structure while providing flexibility in application, as it can be installed on different sprayer models or removed for cleaning and maintenance.
Solution Approach 2:
The patent makes the detection unit dynamically attachable and detachable rather than fixed. This dynamic design allows the system to adapt to different configurations and applications, providing versatility while maintaining relatively simple internal structure. The removable design enables flexible installation and removal without complex mechanisms.
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 effectively prevents damage to the ultrasonic resonator by accurately detecting low liquid levels and powering it off before damage occurs, while also providing a flexible design for the detection unit.
Implementation Method 1
a light source disposed to emit light through the light transparent window for illuminating the gas in the passage such that the gas will reflect the emitted light
Implementation Method 2
an optical sensor disposed to detect a parameter of the reflected light through the transparent window
Implementation Method 3
an ultrasonic resonator, which is disposed in a lower part of the liquid container. A standard implementation of the ultrasonic resonator is a fine mesh containing a plurality of tiny holes. The liquid passes through the tiny holes while the fine mesh resonates at a high frequency (such as ultrasonic), which causes the liquid to be emitted as a gas.
Data Source
AI summary
A sprayer includes: a container; a passage including a transparent window, a first opening, a second opening and a resonator, wherein when liquid in the container is passed through the resonator via the first opening, the liquid is emitted as a gas via the second opening; and a removable detection unit disposed outside of the passage. The removable detection unit includes: a light source for illuminating the gas in the passage; an optical sensor disposed to detect a parameter of light reflected by the gas; and a processor coupled to the optical sensor for stopping the resonator from generating the gas when the parameter is below a threshold. The passage further includes a cavity disposed on a bottom surface of the passage in front of the optical sensor, wherein when the gas in the passage contacts the bottom surface, resultant water vapour will enter the cavity.