Sump Pump Water Vibration Sensing for Level Sensor Fault Detection
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Solution Overview
Problem
Existing sump pump systems lack the ability to automatically detect impending failures or remedy them once detected, leading to potential flooding and costly water damage.
Innovation Solution
The system employs sensors to detect motion and acceleration of water in sump basins, allowing for the estimation of water levels and detection of potential faults in level sensors, thereby activating the sump pump to prevent failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sump pump system uses traditional level sensors to detect water levels, then the pump can activate and deactivate based on high-water and low-water marks, but the system cannot detect sensor faults or impending failures, leading to unreliable operation
Solution Approach 1:
The patent introduces an intermediary sensor (such as an accelerometer or vibration sensor) that indirectly monitors the water level by detecting vibrations caused by water movement. This intermediary sensor provides a backup mechanism to detect when the primary level sensor fails, thereby improving reliability without requiring a complete redundant sensor system.
Solution Approach 2:
The system implements feedback by continuously monitoring sensor outputs and comparing them against expected patterns. When the accelerometer detects abnormal vibration patterns or when the level sensor readings become inconsistent with physical expectations, the system generates feedback signals to alert operators or automatically switch to alternative control modes, ensuring continuous reliable operation.
2Object-affected harmful factors
If the sump pump system activates the pump based on level sensor detection, then water can be removed from the basin, but the system cannot detect sensor malfunctions, resulting in potential flooding and water damage
Solution Approach 1:
The system performs preliminary detection of sensor faults by continuously monitoring the level sensor outputs and accelerometer data before actual flooding occurs. When anomalies are detected indicating sensor malfunction, the system takes preliminary protective actions such as activating the pump early or sending alerts, preventing the harmful outcome of flooding before it can occur.
Solution Approach 2:
The patent implements a cushioning mechanism by having the pump activate at lower water levels when sensor anomalies are detected, creating a safety buffer. This prior cushioning approach ensures that even if the level sensor provides inaccurate readings, the pump will activate early enough to prevent flooding and water damage.
3Reliability
If the system continuously monitors water levels and activates the pump preemptively, then flooding can be prevented, but energy is consumed unnecessarily when the pump runs without need
Solution Approach 1:
The system dynamically adjusts pump operation based on real-time sensor data and fault detection status. When sensors are functioning normally, the pump operates only when water levels reach critical thresholds. When sensor anomalies are detected, the system dynamically switches to a more conservative operation mode with earlier activation, optimizing the balance between reliability and energy consumption based on current system conditions.
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 enables early detection and prevention of sump pump failures, reducing the risk of flooding and water damage, and extending the lifespan of sump pumps by addressing issues before they become critical.
Implementation Method 1
The second sensor (e.g., a force sensor or accelerometer) may be configured to detect motion or acceleration
Implementation Method 2
The controller 138 may include a vibration sensor 128, placed on the sump pump 102 or on a pipe 112
Data Source
AI summary
A sump pump system may detect and utilize motion or acceleration of water in sump basins when implementing control of sump pumps. To detect the motion or acceleration, the sump pump system may utilize a sensor that is configured to detect motion or acceleration, such as an accelerometer or gyroscope. The sump pump system may identify a water level in a sump basin based on the detected motion or acceleration, which may be compared to a reading or expected signal from the sump pump system's “typical” sensor (e.g., float switch) that is used to detect one or more water levels. In this manner, the sump pump system may detect a malfunctioning level sensor that is used by the pump to detect high-water and low-water marks at which the sump pump activates and deactivates, respectively.