Process Transmitter Housing Liquid Detection via Thermal Conductivity

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Solution Overview

Problem

Current methods for detecting moisture in process control transmitters are often unreliable and prone to false alarms, especially due to contamination and humidity, leading to potential damage and output errors.

Innovation Solution

A process transmitter equipped with a liquid detector that uses thermal conductivity to detect moisture within the housing, avoiding electrical conductivity methods and thus reducing sensitivity to contamination and false alarms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical conductivity methods are used to detect moisture, then moisture detection capability is provided, but sensitivity to contamination and false alarms increases

Engineering Contradiction:

Improvemoisture detection accuracyVSAvoidsensitivity to contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces electrical conductivity-based moisture detection with thermal conductivity-based detection. The thermal conductivity sensor measures the thermal properties of the medium surrounding it, which changes when moisture is present, without being affected by electrical contamination or leakage currents that plague electrical conductivity methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the detection parameter from electrical conductivity to thermal conductivity. By measuring thermal conductivity rather than electrical conductivity, the system achieves moisture detection that is not sensitive to electrical contamination, leakage currents, or false alarms associated with electrical-based methods.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If manual multi-step diagnostic operations are used to detect moisture, then moisture presence can be identified, but operational complexity and response time increase

Engineering Contradiction:

Improvemoisture detection accuracyVSAvoiddetection operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs automatic moisture detection through the thermal conductivity sensor integrated into the housing. The controller continuously monitors thermal conductivity changes and automatically determines moisture presence without requiring manual intervention, diagnostic operations, or user expertise, thereby simplifying operation while maintaining reliable detection.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The thermal conductivity sensor provides continuous feedback to the controller about the thermal properties of the surrounding medium. The controller processes this feedback and generates appropriate outputs, creating an automatic monitoring system that eliminates the need for manual diagnostic operations while providing reliable moisture detection.

Inventive Principle:

Principle #23Feedback

3Reliability

If thermal conductivity-based detection is implemented, then false alarms due to contamination are reduced, but device complexity increases

Engineering Contradiction:

Improvedetection accuracyVSAvoiddetection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermal conductivity sensor is integrated directly into the transmitter housing structure, merging the detection function with the existing housing. This integration approach minimizes additional complexity by combining multiple functions into a unified structure rather than adding separate, complex detection subsystems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal conductivity sensor acts as an intermediary element that indirectly detects moisture through thermal conductivity changes in the surrounding medium. This indirect detection method provides reliable moisture identification without requiring direct contact with potentially contaminated electrical components, thereby maintaining simplicity while achieving high reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 thermal conductivity-based liquid detector effectively and accurately detects moisture, preventing damage and ensuring accurate outputs by distinguishing between minor water condensation and actual moisture presence.

Implementation Method 1

A liquid detector is provided which detects a presence of liquid in an electronics housing based on a thermal conductivity of the liquid

Methodology Applied

Scientific EffectThermal conductivity: Conduction (thermal)

Data Source

PatentUS11002582B2Process transmitter with thermal fluid detection for decreasing damage to the process transmitter components

Publication Date: 2021.05.11 ROSEMOUNT INC

AI summary

A process transmitter includes a transmitter housing and a liquid detector coupled to the transmitter housing. The liquid detector includes a temperature sensor configured to generate signals indicative of a presence of liquid within the transmitter housing. The process transmitter also includes a controller coupled to the liquid detector configured to receive the generated signals, determine the presence of liquid within the transmitter housing based on the received signals, and generate an output indicative of the determined presence of liquid within the transmitter housing.