Ultrasonic Flooding Sensor for Light Material Separator
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Solution Overview
Problem
Existing light material separators, such as petrol and grease separators, face challenges with unreliable flood detection due to the sluggishness and inefficiency of conventional conductivity-based sensors, which can lead to operational risks and potential explosions or disruptions, especially in cases of combustible or gaseous substances.
Innovation Solution
An ultrasonic sensor is used as a flooding sensor, installed above the operating free level, emitting signals only when in contact with liquid or light materials, providing precise and reliable detection of flooding and its extent, while meeting explosion protection regulations with low energy consumption and minimal additional effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductivity-based flood sensors are used, then flooding detection is provided, but the detection is sluggish and unreliable in certain operating states
Solution Approach 1:
The patent replaces conductivity-based electrical sensors with ultrasonic sensors that use acoustic waves to detect flooding. This substitution eliminates the sluggish and unreliable conductivity measurements, providing rapid and reliable detection of liquid levels and flooding conditions in the separator tank.
Solution Approach 2:
The patent changes the detection parameter from electrical conductivity to ultrasonic wave propagation characteristics. By measuring the speed and reflection of ultrasonic waves through different media (air, water, fat layers), the system achieves reliable and rapid flooding detection that is not dependent on the electrical properties of the substances being separated.
2Measurement precision
If ultrasonic transducers are installed inside the tank, then fill level and layer thickness can be determined, but the ultrasonic transducer becomes inoperable when flooding occurs up to it
Solution Approach 1:
The patent positions the ultrasonic transducer in the air space above the operating free level rather than immersing it in the liquid or fat layers. This spatial repositioning allows the sensor to remain operational during flooding by detecting the rising liquid level from above, preventing the inoperability issue that occurs when transducers are installed inside the liquid phase.
Solution Approach 2:
The patent uses the air space above the operating free level as an intermediary medium for ultrasonic wave propagation. By installing the transducer in this air space, the system maintains a reliable transmission medium (air) even when flooding occurs, allowing continuous monitoring without the transducer becoming inoperable.
3Reliability
If conventional flood sensors are used, then flooding detection is provided, but high effort and accompanying measures are required for reliable operation
Solution Approach 1:
The ultrasonic transducer installed in the air space serves multiple functions: it detects flooding conditions, measures fill levels, and monitors layer thicknesses. This multi-functionality eliminates the need for separate sensors for different measurement tasks, reducing device complexity while maintaining high reliability.
Solution Approach 2:
The ultrasonic sensor system automatically adapts to different operating conditions by measuring wave propagation through the air space and detecting changes in the medium. The system requires no manual calibration or adjustment and provides reliable operation across various flooding scenarios without accompanying measures or complex maintenance procedures.
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 ultrasonic sensor effectively detects flooding occurrences and trends, enabling timely countermeasures and improving operational reliability by providing informative and rapidly responding signals, thus enhancing the monitoring and maintenance of light material separators.
Implementation Method 1
The ultrasonic sensor measures with ultrasonic pulses in the air space of the container... the propagation time of each ultrasonic impulse, which is reflected from the level of the filling level or the interface to the ultrasonic transducer
Implementation Method 2
the propagation time of each ultrasonic impulse, which is reflected from the level of the filling level or the interface to the ultrasonic transducer, and supplies a signal dependent on the propagation time
Data Source
AI summary
The separator (A) has a container (1) including a liquid inlet (3) and a liquid drain (4) in which an operation-free surface (F) is defined. A flood-sensor (S) is provided above the operation-free surface of container. The flood-sensor comprises ultrasonic sensor unit (8) for detecting the flooding levels (U1, U2) of liquid.