Thermal Fluid Level Sensor Eliminates Mechanical Wear
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Solution Overview
Problem
Mechanical fluid level sensors are prone to wear and failure due to moving parts, making them unreliable for accurately measuring fluid levels in containing volumes.
Innovation Solution
A fluid level sensor system utilizing a thermal path component with a heat source and temperature sensors to maintain a predetermined temperature difference, converting the energy required to maintain this difference into a proportional output indicating the fluid level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical components are used in fluid level sensors, then the sensor can measure fluid levels, but the components are prone to wearing and failure
Solution Approach 1:
The patent replaces the mechanical float-potentiometer system with a thermal conduction-based sensing system. A thermal path component extends into the fluid, and a heater maintains a temperature differential. The fluid level is detected by measuring the energy required to maintain this temperature difference, eliminating moving mechanical parts and improving reliability.
Solution Approach 2:
The invention extracts and removes the problematic mechanical components (float, pivot arm, wiper mechanism) from the sensor system. By using a stationary thermal path component and electronic temperature sensing, the patent eliminates the mechanical parts that cause wear and failure, while retaining the fluid level measurement function.
2Measurement precision
If mechanical components are used in fluid level sensors, then the sensor can indicate fluid level, but the moving parts cause wear and failure
Solution Approach 1:
The patent substitutes the mechanical measurement system with a thermal field-based system. The stationary thermal path component conducts heat into the fluid, and temperature sensors measure the energy required to maintain a temperature differential. This eliminates moving parts, extending component lifespan while maintaining measurement precision.
Solution Approach 2:
The thermal path component serves dual functions: it acts as both the heating element and the temperature sensing element. The same component that conducts heat into the fluid also provides the thermal path for temperature measurement, eliminating the need for separate mechanical measurement mechanisms and reducing wear.
3Reliability
If a float and pivot arm mechanism are used, then fluid level can be measured, but the mechanical nature leads to wearing and failure
Solution Approach 1:
The patent replaces the float-pivot arm mechanical system with a stationary thermal conduction system. The thermal path component remains fixed while a heater and temperature sensors detect fluid level changes through thermal energy transfer. This substitution eliminates mechanical wear, friction, and moving part failures, significantly improving reliability.
Solution Approach 2:
The patent introduces thermal energy as an intermediary to transfer information about fluid level. Instead of mechanical contact between the float and potentiometer, the thermal path component conducts heat into the fluid, and the energy required to maintain temperature differential indirectly indicates fluid level, eliminating direct mechanical interaction and wear.
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 approach provides a reliable and accurate method for measuring fluid levels by minimizing mechanical components and using thermal energy to indicate fluid level changes, reducing wear and improving measurement precision.
Implementation Method 1
a heat source operably coupled to the thermal path component... maintaining a predetermined temperature difference between the control temperature and the reference ambient temperature by controlling the heat source
Implementation Method 2
a thermal path component at least partially disposed within a fluid containing volume... an energy level required to maintain the predetermined temperature difference is converted to a fluid level
Data Source
AI summary
A fluid level sensor system includes a thermal path component disposed at least partially within a fluid containing volume, the thermal path component including a heat source operably coupled thereto and a control temperature sensor for sensing a control temperature of the thermal path component. Also included is a reference temperature sensor for sensing a reference ambient temperature. Further included is a controller in operable communication with the control temperature sensor, the heat source and the reference temperature sensor, wherein the controller maintains a predetermined temperature difference between the control temperature and the reference ambient temperature by controlling the heat source, wherein an energy level required to maintain the predetermined temperature difference is converted to a fluid level within the fluid containing volume.