Tubular Fluid Level Sensor for Contamination-Resistant Valve Control
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Solution Overview
Problem
Existing fluid level sensors for controlling valves are bulky, heavy, and unsuitable for non-conductive fluids, leading to inaccurate level detection and potential underpressure issues due to contamination and residual water detection, particularly in space-restricted applications like aircraft.
Innovation Solution
A compact tubular housing with an axial flow channel and a sensor channel, where a first sensor part moves axially in response to fluid pressure, aligning with a second sensor part at a predetermined pressure level to activate a control signal for the valve, using RFID technology or other sensors that communicate through pressure-induced alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is mounted within the flow line of the fluid, then the sensor can detect fluid level, but the sensor disrupts fluid flow and becomes contaminated by particles and debris
Solution Approach 1:
The sensor is extracted from the main flow line and placed in a separate sensor channel that branches off from the flow channel. This allows the sensor to detect fluid level in the main channel without being directly exposed to the flow, eliminating flow disruption and contamination risks while maintaining detection accuracy.
2Measurement precision
If a conductive sensor device is used in a wye fitting branch, then water level can be detected, but the sensor cannot detect non-conductive fluids and is affected by contaminants
Solution Approach 1:
The sensor assembly is designed to detect fluid levels in both conductive and non-conductive fluids. The sensor channel configuration and sensor type selection enable universal applicability across different fluid types, eliminating the limitation of conductive sensors while maintaining accurate detection capability.
3Measurement precision
If a wye fitting with sensor branch is used, then fluid level sensing is achieved, but the assembly becomes bulky, heavy, and occupies large space
Solution Approach 1:
The sensor channel is nested within the flow channel structure, with the sensor positioned in the sensor channel that branches from the flow channel. This nested configuration allows the sensor assembly to be compact and integrated into the existing flow path without requiring additional bulky external components, reducing overall weight and space occupation.
4Measurement precision
If residual water remains in the wye fitting branch, then the conductive sensor detects it as high fluid level, but this causes false valve opening and underpressure upstream
Solution Approach 1:
The sensor is extracted from the main flow path and positioned in a separate sensor channel. This extraction prevents residual water in the main flow channel from falsely triggering the sensor, as the sensor only detects fluid level when it rises into the sensor channel through the communication opening, ensuring reliable valve control.
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 solution provides accurate and compact fluid level sensing for all types of fluids, including non-conductive ones, reducing weight and space requirements while preventing false triggers from contamination or residual water, ensuring reliable valve operation.
Implementation Method 1
a first sensor part located in the sensor channel such that the first sensor part can move axially within the sensor channel responsive to pressure of the fluid in the flow channel acting on the first sensor part in the sensor channel
Implementation Method 2
when the fluid pressure is at a predetermined level, the first sensor part is at a position in the sensor channel adjacent the second sensor part such that the first and second sensor parts communicate with each other
Data Source
Figure 1
Figure 2~3
Figure 4~5B
AI summary
A fluid level sensor assembly comprising includes a tubular housing (100) arranged to be fitted into a fluid flow path of a system between a fluid line an inlet (300) to a valve (1'), wherein the tubular housing (100) defines an axial flow channel (400) extending through the tubular housing from a first end (101) to a second end (102), along an axis A, for fluid to flow from the fluid line of the system to the valve inlet (300), the tubular housing (100) further comprising a sensor channel (500) extending from the second end (102) of the flow channel (400) towards the first end substantially parallel to, and in fluid communication with the axial flow channel (400), wherein the assembly further comprises a first sensor part (600) located in the sensor channel such that the first sensor part can move axially within the sensor channel responsive to pressure of the fluid in the flow channel acting on the first sensor part in the sensor channel, and a second sensor part (700) provided on the tubular housing (100) at an axial position between the second end (102) and the first end (101) selected such that when the fluid pressure is at a predetermined level, the first sensor part is at a position in the sensor channel adjacent the second sensor part such that the first and second sensor parts communicate with each other.