Ultrasonic Sprayer Optical Liquid Level Detection
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Solution Overview
Problem
Existing 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 detection system using a light source and optical sensor to measure the intensity of the gas emitted by the sprayer, with a processor controlling the resonator's power based on thresholds for liquid level detection, preventing erroneous power-on and protecting the resonator.
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. Instead of using electrodes to measure liquid level through conductivity changes, the system uses a light source and optical sensor to detect liquid level by measuring light transmission through the liquid. This substitution eliminates the problem of bubbles causing false positive readings, as optical transmission is not affected by bubble presence in the same way electrical conductivity is.
Solution Approach 2:
The patent introduces light as an intermediary medium for detection. Instead of directly measuring electrical conductivity which is affected by bubbles, the system uses light transmission as an intermediary measurement that correlates with liquid level but is not directly affected by bubble presence. The optical sensor detects light intensity changes that indicate liquid level without being fooled by bubble coverage.
2Device complexity
If the resonator continues to operate when liquid level is low, then the system remains simple, but the resonator is damaged due to insufficient liquid
Solution Approach 1:
The patent implements preliminary detection and action before the resonator can be damaged. The optical detection system continuously monitors liquid level, and when the liquid level falls below a safe threshold, the system preemptively powers off the resonator. This preliminary action prevents the resonator from operating under conditions that would cause damage, rather than reacting after damage has occurred or relying on simple continuous operation.
Solution Approach 2:
The patent establishes a feedback control loop where the optical sensor continuously monitors liquid level and provides feedback to the control system. Based on this feedback, the system dynamically adjusts the resonator operation - powering it on when liquid level is sufficient and powering it off when liquid level is low. This feedback mechanism ensures the resonator only operates under safe conditions, protecting reliability while maintaining appropriate system complexity.
3Ease of repair
If a removable detection unit is implemented, then the system becomes more flexible and easier to maintain, but the device complexity increases
Solution Approach 1:
The patent segments the detection system into a separate, removable detection unit that can be independently handled from the main resonator assembly. The detection unit includes the optical sensor, light source, and associated electronics, and can be removed as a single module for maintenance or replacement. This segmentation improves ease of repair and maintenance while adding only moderate complexity, as the modular design allows for standardized interfaces and simplified assembly/disassembly procedures.
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
Accurately detects low liquid levels, preventing resonator damage by powering it off when necessary, and offering a flexible, removable design for improved accuracy and user feedback.
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 arranged to contain liquid; a passage including a transparent window, a first opening, a second opening and a resonator, wherein when the 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 detection unit disposed outside of the passage. The detection unit includes: 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; an optical sensor disposed to detect a parameter of the reflected light through the transparent window; and a processor coupled to the optical sensor for stopping the resonator from generating the gas when the parameter of the reflected light is below a first threshold corresponding to a specific level of liquid within the container.