Universal Superheat Sensor with Automatic Fluid Detection
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Solution Overview
Problem
Existing superheat sensors in fluid systems, particularly in HVAC systems, lack automatic fluid-type detection, high sensitivity, and resolution across a wide range of pressures, and do not store superheat and related parametric history or provide industry-standard reporting options.
Innovation Solution
A universal superheat sensor with a housing, integrated pressure and temperature sensors, a processor, and communication module that automatically detects multiple fluid types, calculates superheat, and stores data, including alarm conditions, without the need for recalibration, using industry-standard reporting and storing information in a local memory device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pressure sensor and single temperature sensor are used, then device complexity is reduced, but measurement precision and sensitivity across wide pressure ranges deteriorate
Solution Approach 1:
The patent applies universality by designing a single pressure sensor and single temperature sensor that can accurately measure superheat across multiple fluid types and wide pressure ranges (0-100 psig). The sensor system is made multi-functional to handle different refrigerants (R-134a, R-410A, R-404A) without recalibration, allowing one sensor to perform what traditionally required multiple specialized sensors.
2Adaptability or versatility
If automatic fluid-type detection is implemented, then adaptability improves, but device complexity increases
Solution Approach 1:
The sensor system applies self-service through automatic fluid-type detection that requires no user input or manual configuration. The processor automatically identifies the fluid type based on measurements from the single pressure sensor and single temperature sensor, and autonomously selects appropriate superheat calculation parameters, eliminating the need for complex manual setup procedures.
Solution Approach 2:
The patent applies preliminary action by pre-programming the processor with fluid identification algorithms and superheat calculation parameters for multiple refrigerant types. The system performs preliminary detection of fluid type upon connection, before superheat measurement begins, allowing it to automatically configure itself for the specific fluid being measured.
3Loss of information
If superheat and parametric history are stored in local memory, then information retention improves, but device complexity increases
Solution Approach 1:
The patent applies copying by creating digital replicas of superheat measurements and parametric data in local memory. The processor continuously copies measurement data from the sensors into stored historical records, allowing the system to retain and retrieve past measurements without adding physical complexity to the sensing mechanism itself.
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 sensor provides accurate and sensitive superheat measurements across various fluid types and pressures, storing historical data and reporting in industry-standard formats, ensuring efficient operation and user alerts for system anomalies.
Implementation Method 1
a pressure sensor mounted within the housing... A pressure of the fluid in the fluid system is sensed with the pressure sensor
Implementation Method 2
A temperature of the fluid in the fluid system is sensed with one of an internal temperature sensor mounted within a housing of the superheat sensor and an external temperature sensor mounted outside of the housing of the superheat sensor
Implementation Method 3
A superheat of the fluid in the fluid system is then calculated... The processor calculates the superheat of the fluid based on the pressure and temperature values
Data Source
AI summary
A method of sensing superheat includes the steps of: (a) connecting a fluid inlet member of a superheat sensor to one of a plurality of fluid systems; (b) allowing fluid to flow from the fluid system to which the superheat sensor is connected to the superheat sensor; (c) sensing a temperature of the fluid in the fluid system with one of an internal temperature sensor mounted within a housing of the superheat sensor and an external temperature sensor mounted outside of the housing of the superheat sensor; and (d) calculating a superheat of the fluid in the fluid system.