Ultrasonic Liquid Sensor with Intermediate Mounting Plates
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Solution Overview
Problem
Existing ultrasonic liquid sensors face issues with leakage and distortion of ultrasonic waves due to insecure connections and material interference when integrated into tubes, requiring costly and time-consuming installation methods that compromise the structural integrity of the tube.
Innovation Solution
The ultrasonic liquid sensor employs intermediate mounting plates made from conductive or non-conductive materials that maintain direct physical contact with the tube sidewalls, allowing ultrasonic signals to pass through without distortion, and uses a support assembly or housing base for secure attachment without screws or adhesives, ensuring consistent contact and signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transducers are applied directly to the tube sidewalls with fastening agents such as screws or chemical means, then secure connection is achieved, but the ultrasonic waves are absorbed and/or distorted
Solution Approach 1:
The patent introduces intermediate mounting plates as mediators between the transducers and the tube sidewalls. These plates are specifically designed to be ultrasonic-transparent (made from materials like PTFE, PEEK, or other low-acoustic-impedance materials) to allow ultrasonic waves to pass through without significant absorption or distortion, while still providing secure mechanical attachment points for the transducers.
2Reliability
If a joint sensor system is integrated into the tube by removing a section and joining the sensor, then effective detection is achieved, but the tube structural integrity is compromised and installation is time-consuming
Solution Approach 1:
The patent segments the sensor system into separate mounting plates that can be independently attached to the tube exterior, eliminating the need to cut or modify the tube structure. This allows the tube to maintain its structural integrity while the sensor components are mounted on the outer surface through clamps or brackets.
Solution Approach 2:
The mounting plates are designed to wrap around or clamp onto the tube exterior, creating a nested configuration where the sensor assembly encompasses the tube without penetrating or compromising it. This allows effective ultrasonic detection while preserving the tube's structural continuity.
3Reliability
If fastening agents are used to attach transducers to the tube, then secure connection is achieved, but the installation becomes expensive and time-consuming
Solution Approach 1:
The intermediate mounting plates serve as reusable intermediary components that can be attached to the tube using simple mechanical fastening methods. Once the mounting plates are in place, multiple transducers can be quickly attached to the plates without requiring repeated application of fastening agents, significantly reducing installation time and cost.
4Adaptability or versatility
If the sensor is made reusable for various tube sizes and shapes, then adaptability is improved, but maintaining consistent contact and signal integrity becomes more difficult
Solution Approach 1:
The mounting plates are designed with adjustable and flexible mounting mechanisms that can adapt to different tube diameters and shapes. The plates can be positioned and secured at various locations around the tube, allowing the sensor assembly to maintain consistent contact with the tube surface regardless of the specific tube dimensions, thereby preserving signal integrity across diverse applications.
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 provides a cost-effective, easy-to-install, and reusable sensor that maintains tube integrity, effectively detecting liquid presence without attenuating or distorting ultrasonic signals, and can be adapted for various tube sizes and shapes without the need for cutting.
Implementation Method 1
The first transducer element, mounted to the first intermediate mounting plate, is configured to transmit an ultrasonic signal through the first intermediate mounting plate and the first sidewall of the tube
Implementation Method 2
The second transducer element, mounted to the second intermediate mounting plate, is configured to receive the ultrasonic signal passing through the second sidewall of the tube and through the second intermediate mounting plate
Data Source
AI summary
An ultrasonic liquid sensor for detecting liquid in a tube having sidewalls includes a first intermediate mounting plate held in physical communication with a first sidewall of the tube, a second intermediate mounting plate held in physical communication with the second sidewall of the tube. The plates are configured to allow the ultrasonic signal to pass therethrough. The sensor also includes a first and a second transducer element. The first and second transducer elements are mounted to the intermediate mounting plates and are configured to receive the ultrasonic signal passing through the sidewalls of the tube as well as the intermediate mounting plates to determine the presence or absence of liquid in the tube. The sensor can be enclosed in a self-contained unit and a support assembly can be used and formed of metal material or non-metal material to interface with the sensor and a secondary circuit.