Strain Gauge Pump Control Switch for Harsh Environments
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Solution Overview
Problem
Existing pump control switches fail to provide reliable and long-lasting operation in harsh environments, leading to non-functional pumps and supply deficiencies in commercial and industrial settings.
Innovation Solution
A solid state pump control system utilizing a strain gauge as a transducer to sense fluid levels, coupled with electronic control and switching circuitry, including high power semiconductor switches and a relay, to manage motor currents and withstand harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional switches are used in harsh environments, then the device complexity remains low, but the reliability deteriorates due to switch failures
Solution Approach 1:
The patent replaces mechanical switch contacts with a strain gauge-based sensing system that detects fluid levels and triggers electronic switching. The strain gauge measures diaphragm deformation caused by fluid pressure, converting mechanical displacement into an electrical signal that controls pump operation, thereby eliminating mechanical wear and contact arcing issues
Solution Approach 2:
The patent introduces a diaphragm as an intermediary element between the harsh fluid environment and the sensing mechanism. The diaphragm transmits fluid pressure changes to the strain gauge while isolating the electronic components from direct exposure to corrosive fluids, extreme temperatures, and other harsh environmental factors
2Duration of action of stationary object
If mechanical switches are used to control pump motors, then the device complexity remains low, but the switches suffer from arcing and electro-ablation reducing their lifespan
Solution Approach 1:
The patent replaces mechanical switch contacts with a strain gauge-based sensing system that detects fluid levels and triggers electronic switching. The strain gauge measures diaphragm deformation caused by fluid pressure, converting mechanical displacement into an electrical signal that controls pump operation, thereby eliminating mechanical wear and contact arcing issues
Solution Approach 2:
The patent employs a relay as a sacrificial component designed to fail before the main control electronics. The relay handles the high-current motor switching and can be replaced independently if it fails, protecting the more expensive strain gauge and electronic circuitry from damage due to arcing and electro-ablation
3Measurement precision
If simple switch configurations are used, then the manufacturing cost remains low, but the switches fail to provide accurate fluid level detection in harsh environments
Solution Approach 1:
The patent utilizes the strain gauge's ability to measure changes in physical parameters (diaphragm deformation, fluid pressure) and converts these mechanical parameter changes into precise electrical signals. The system detects subtle variations in fluid level by measuring corresponding changes in diaphragm strain, enabling accurate detection even in harsh environmental conditions
Solution Approach 2:
The patent concentrates the sensing function in a localized strain gauge element that directly contacts or closely monitors the diaphragm deformation at the critical measurement point. This localized high-precision sensing approach provides accurate fluid level detection without requiring complex system-wide instrumentation
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 system ensures reliable pump operation by accurately responding to fluid levels, diverting inrush currents, and protecting against arcing and electro-ablation, thereby extending switch lifespan and maintaining pump functionality.
Implementation Method 1
incorporate a strain gauge as a transducer to convert an environment condition, such as a level of a fluid, to an electrical signal
Data Source
AI summary
A control switch incorporates a solid state transducer, a strain gauge. The transducer responds to a local environmental condition, such as fluid level, or pressure and exhibits a parameter change which can be detected as an electrical output. Control circuits coupled to the transducer can sense the parameter change and switch a source of electrical energy to a load in response thereto.