Wireless Tank Level Detection for Liquid Industrial Vacuum Cleaners
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Solution Overview
Problem
Conventional industrial vacuum cleaners for liquids face issues with unreliable wired connections and turbulent liquid motion causing false triggers in the liquid level detection system, leading to incorrect operation and potential damage.
Innovation Solution
The implementation of a wireless electromagnetic wave-based detection system using a circuit board emitter and receiver, with a micro switch and float, ensures reliable transmission of the liquid level signal to the control unit, preventing turbine activation and deactivation due to liquid waves, and includes resettable blocking means and visual signaling for operator convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wired connection is used to transmit the control signal from the detection device to the electrical control unit, then the device structure is simple and easy to manufacture, but the connection is unreliable and susceptible to malfunctions, detachment, and operator errors
Solution Approach 1:
The patent replaces the mechanical wired connection system with an electromagnetic wave-based wireless transmission system. The emitter generates electromagnetic waves that carry the control signal from the detection device to the electrical control unit, eliminating physical cables and connectors. This substitution resolves the reliability issues of wired connections while managing the introduced complexity through integrated electromagnetic transmission components.
2Reliability
If the float-based detection device is used in turbulent liquid conditions, then the liquid level can be detected, but the liquid waves cause continuous false triggering of the micro switch, leading to continuous activation and deactivation of the turbine
Solution Approach 1:
The patent replaces the direct mechanical linkage between the float and micro switch with an electromagnetic wave-based signal transmission system. The emitter detects float position and transmits signals wirelessly to the control unit, which can implement software-based filtering to ignore transient false triggers caused by liquid turbulence, thereby maintaining operational stability while preserving detection accuracy.
Solution Approach 2:
The wireless transmission system enables the electrical control unit to receive continuous feedback from the detection device and implement intelligent signal processing. The control unit can analyze the received signals, distinguish between genuine level changes and false triggers from turbulence, and make informed decisions about turbine control, improving operational stability.
3Ease of operation
If the wired connection is exposed outside the vacuum cleaner, then the detection device can function, but the cable is vulnerable to accidental tampering, detachment, and incorrect reconnection by operators
Solution Approach 1:
The patent eliminates exposed mechanical cables by implementing wireless electromagnetic transmission. The emitter is integrated within the detection device housing, and signals are transmitted through electromagnetic waves to the control unit, removing the vulnerable external cable infrastructure while maintaining full operational functionality for tank maintenance and detection.
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 enhances reliability and safety by eliminating cable malfunctions and reducing energy consumption, preventing unnecessary turbine activation and deactivation, and facilitating maintenance by ensuring the control signal is managed correctly, thus preventing damage from excess liquids.
Implementation Method 1
a float, provided inside said housing, and movable vertically as a result of the hydrostatic thrust exerted on it by the liquid increasing in the tank
Implementation Method 2
a micro switch, also provided in said housing, generally of reed type, on the cylindrical body of which said float is movable, adapted to cooperate with said float, which comprises a magnet adapted to cause the change of status of said micro switch
Implementation Method 3
said detection device comprises a circuit board comprising an emitter of an electromagnetic wave control signal, said control signal being generated as a result of the change in status of said micro switch
Implementation Method 4
said electrical control unit comprises a receiver adapted to receive said electromagnetic wave control signal
Implementation Method 5
The turbine draws in air, creating a vacuum pressure in the collection tank: the vacuumed air draws with it the liquids, which fill said tank
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Industrial vacuum cleaner (1) for liquid substances with detection device (2) of the level of filling of its collection tank. Said vacuum cleaner provided with a vacuum turbine (3) comprises: - a collection tank (4) of the vacuumed liquid products (L); - an electrical control unit (5) for controlling the various functions; - a detection device (2) of the level of liquid reached in said tank (4), comprising a housing (6) obtained in said tank (4), a float (7) and a micro switch (8), wherein said float (7), rising as a result of the increase in the level of liquid (L), cooperates with said micro switch (8) to change its status and generate a control signal, manageable by said electrical control unit (5), to stop said vacuum turbine (3) upon reaching a predefined maximum level of filling; - transmission means of said control signal from said detection device (2) to said electrical control unit (5). Said detection device (2) comprises a circuit board comprising an emitter (9) of an electromagnetic wave control signal, said control signal being generated as a result of the change in status of said micro switch (8). Said electrical control unit (5) comprises a receiver (10) adapted to receive said electromagnetic wave control signal, and said transmission means of said control signal are of wireless type.