Steam Generator Water Level Control in Clothes Care Cabinets
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Solution Overview
Problem
The existing clothes treating apparatuses face issues with inaccurate water level sensing in steam generators, leading to potential water overflow or insufficiency, which can cause heater breakdowns and increase manufacturing costs, due to impurities degrading sensor accuracy and difficulty in maintenance.
Innovation Solution
A control algorithm that complements erroneous water level sensing by supplying water based on the amount of steam generated and using multiple water level sensors with different lengths to process sensing results, preventing heat application without water and adjusting water supply to prevent overflow, without requiring additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single water level sensor is used in the steam generator tank, then the manufacturing cost is reduced, but the measurement precision of water level deteriorates due to impurities gathering in the tank
Solution Approach 1:
The patent divides the water level sensing function into multiple segments by using three water level sensors (first, second, and third sensors) positioned at different heights in the tank. This segmentation allows the system to detect water levels at multiple thresholds, compensating for the degradation of individual sensors caused by impurities and providing more reliable overall measurement precision without requiring a single highly precise sensor.
Solution Approach 2:
The control unit continuously monitors the output signals from all three water level sensors and uses feedback logic to determine the actual water level. When impurities cause a sensor to malfunction, the feedback mechanism cross-checks the readings from other sensors to identify and compensate for erroneous signals, maintaining accurate water level detection throughout the tank's operational life.
2Reliability
If the tank structure is made sealed and integrated within the apparatus, then the reliability is improved, but the ease of operation for maintenance deteriorates as impurities cannot be easily removed
Solution Approach 1:
The patent implements a self-service maintenance mechanism where the control unit automatically detects sensor malfunctions caused by impurities and triggers a cleaning operation. The cleaning unit is activated to spray cleaning solution into the tank, automatically removing impurities from the sensor surfaces without requiring manual disassembly or user intervention, thus maintaining reliability while simplifying maintenance.
Solution Approach 2:
The system incorporates periodic cleaning cycles where the cleaning unit is activated at regular intervals or when sensor degradation is detected, to remove accumulated impurities from the tank interior and sensor surfaces. This periodic maintenance action prevents long-term degradation of sensor accuracy while maintaining the sealed, integrated tank structure.
3Device complexity
If water supply is controlled solely based on water level sensor readings, then the device complexity is reduced, but the reliability deteriorates when sensors provide erroneous high water level readings
Solution Approach 1:
The control unit uses feedback from multiple water level sensors to cross-validate readings before actuating the water supply valve. The control logic analyzes patterns in sensor outputs and compares them against expected water level relationships, identifying erroneous high readings caused by impurities. This feedback-based validation ensures reliable water supply control while adding minimal complexity to the system.
Solution Approach 2:
The control unit acts as an intermediary between the water level sensors and the water supply valve, processing and validating sensor readings before triggering water supply actions. This intermediary layer filters out erroneous sensor signals caused by impurities and ensures that water supply decisions are based on accurate water level information, improving reliability without significantly increasing device complexity.
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 accurately senses the water level in the steam generator tank, prevents heater breakdowns, and avoids water overflow, maintaining apparatus performance without increasing manufacturing costs, while alerting users to potential issues.
Implementation Method 1
the water level sensor is configured as at least one electrode, and a control unit of the clothes treating apparatus senses information related to a water level within the tank using a current flowing in the electrode
Implementation Method 2
a heater generating heat applied to the tank
Implementation Method 3
a tank for accommodating water to generate steam
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A clothes treating apparatus includes a case (10) including a treatment chamber (12) holding clothes, a steam unit (40) supplying steam to the treatment chamber, a blowing unit (30) intaking air from the inside of the treatment chamber, a heat pump unit (50) heating air intaken by the blowing unit and discharging heated air to the inside of the treatment camber, and a control unit (60) controlling the steam unit, the blowing unit, and the heat pump unit, wherein when the heat pump unit is driven after the steam unit is driven, the control unit supplies water to the steam unit after driving of the heat pump unit terminates.