Dielectric liquid level sensor and method

• US 4,806,847 A
• Filed: 12/09/1986
• Issued: 02/21/1989
• Est. Priority Date: 12/09/1986
• Status: Expired due to Fees

• Current Assignee: Caterpillar Incorporated, Sensor Electronics Corp.
• Original Assignee: Caterpillar Incorporated
• Inventors: Mawet, Patrick H., Clow, Charles R., Atherton, Kim W.
• Primary Examiner(s): Eisenzopf, Reinhard J.
• Assistant Examiner(s): Harvey, Jack B.
• Application Number:
  US06/939,534
• Time in Patent Office: 805 Days
• Field of Search: 324/61 P, 324/61 R, 324/60 CD, 73/304 C, 73/304 R, 73/1 R, 340/59, 340/618, 340/620, 361/284
• US Class Current: 73/304.00C
• CPC Class Codes: G01F 23/04 by dip members, e.g. dip-sticks
• CPC Class Codes: G01F 23/266 measuring circuits therefor
• CPC Class Codes: G01F 23/268 mounting arrangements of probes
• CPC Class Codes: G01F 25/24 Testing proper functioning of electronic circuits

Abstract

A sensor for sensing the level of oil or transmission fluid under both normal and extreme temperature conditions. The only active components of the sensor have input and leakage currents substantially lower than those of diodes and current sources under high temperature conditions. The sensor has a probe, including a pair of electrodes forming a level detecting capacitor, adapted to extend in the vessel to detect the level of the liquid. A reference capacitor is included which has a capacitance substantially the same as the capacitance of the level detecting capacitor when no dielectric liquid is present between the electrodes of the level detecting capacitor. Circuitry is provided for measuring the capacitance of each capacitor and for deriving from the capacitance measurements a signal proportional to the level of the dielectric liquid at the sensor. Circuitry is also provided for testing whether the reference capacitor is operating properly. One of the electrodes of the level detecting capacitor is insulated to render the output of the sensor independent of high temperature conductivity effects. Structure and a method are provided for compensating for varying dielectric constants of the oil or transmission fluid in which the sensor is immersed.

Claims

1. A sensor for sensing the level of a dielectric liquid in a vessel such as oil, transmission fluid or the like comprising:

a sensor body adapted to be mounted with respect to the vessel containing the dielectric liquid whose level is to be measured;

a probe including first and second electrodes forming a level detecting capacitor, said probe being secured to the sensor body and being adapted to be at least partially immersed in the liquid, when liquid is present, to detect the level of the liquid, the capacitance of the level detecting capacitor being a function of the level of the dielectric liquid in which said level detecting capacitor is immersed;

a reference capacitor disposed in said sensor body such that its capacitance is not affected by the presence or absence of the dielectric liquid, the capacitance of said reference capacitor being substantially the same as the capacitance of the level detecting capacitor when no dielectric liquid is present between the electrodes of the level detecting capacitor;

an oscillator mounted in the sensor body for providing a rectangular waveform having a charging portion and a second portion, and means for directly applying the waveform to each of said capacitors to charge the capacitors during the charging portion of each cycle of the waveform and to allow the capacitors to discharge during the second portion of each cycle;

capacitance measuring means for measuring the capacitance of each capacitor whose capacitance is to be measured, said measuring means providing an output signal having a parameter proportional to the measured capacitance of each capacitor and which signal is unaffected by the charge on each such capacitor during the charging portion of the rectangular waveform provided by the oscillator; and

subtracting means for effectively subtracting the signal parameter representing the capacitance of said reference capacitor with respect to the signal parameter representing the capacitance of the level detecting capacitor to give a resulting signal representative of the level of the dielectric liquid at the sensor.

2. The sensor as set forth in claim 1 wherein the reference capacitor is a temperature stable, NPO-type capacitor.

3. The sensor as set forth in claim 1 wherein the oscillator is a relaxation oscillator comprised of components having leakage currents substantially lower than those of diodes and current sources under high temperatures.

4. The sensor as set forth in claim 1 wherein said capacitance measuring means includes a separate measurement circuit for each capacitor.

9. The sensor as set forth in claim 1 wherein the subtracting means is comprised of components having leakage currents substantially lower than those of diodes and current sources under high temperatures.

10. The sensor as set forth in claim 1 further including means for testing whether the reference capacitor is operating properly.

11. The sensor as set forth in claim 10 wherein the testing means includes means for supplying a reference voltage to the subtracting means in place of the signal parameter representing the capacitance of the level detecting capacitor, whereby the output of the subtracting means is a function of whether the reference capacitor is operating properly.

12. The sensor as set forth in claim 11 wherein said the capacitance measuring means includes a plurality of comparators, the signal parameter representing the capacitance of the reference capacitor is a voltage, and including a reference voltage supplied to the comparators, the reference voltage being less than the voltage representing said capacitance with the reference capacitor is operating properly.

13. The sensor as set forth in claim 12 wherein the reference voltage supplying means includes an externally operable switching device connected between the reference voltage source and an input of the comparator so that the application of the reference voltage to the comparator may be externally controlled.

14. The sensor as set forth in claim 10, wherein the testing means includes means for detecting a break in the circuit between the level detecting capacitor and the capacitance measuring means.

15. The sensor as set forth in claim 1 further including a third electrode disposed in the probe at a position in which the third electrode is normally surrounded by the dielectric liquid, wherein the third electrode is radially spaced from and coaxial with one of the first or second electrodes to form a third, dielectric liquid filled capacitor whose capacitance is normally a function of the dielectric constant of the particular dielectric liquid whose level is being sensed;

further including a second reference capacitor disposed in the sensor such that its capacitance is not affected by the presence or absence of the dielectric liquid, the capacitance of the second reference capacitor being substantially the same as the capacitance of the third capacitor when no dielectric liquid is present between the electrodes of the third capacitor wherein said oscillator applies the waveform to the third dielectric filled capacitor and the second reference capacitor, and the capacitance measuring means measures the capacitance of the third dielectric filled capacitor and the second reference capacitor and has output signals with parameters proportional to the measured capacitances of each of the capacitors;

further including second means for substracting the signal parameter representing the capacitance of the second reference capacitor from the signal parameter representing the capacitance of the dielectric filled capacitor to give a signal proportional to the dielectric constant of the dielectric liquid, the ratio of the signals from the first subtracting means and the second subtracting means being substantially independent of the dielectric constant of the dielectric liquid.

16. The sensor as set forth in claim 15 including means for detecting a break in the circuit between the third capacitor and the capacitance measuring means.

17. A sensor as set forth in claim 15, wherein the gap between the electrodes of the third, dielectric filled capacitor is sized to provide significant clinging of the dielectric liquid between the electrodes when the level of liquid in the vessel falls below the level of the third capacitor.

18. The sensor as set forth in claim 1 wherein the sensor body is electrically isolated from the vessel.

19. The sensor as set forth in claim 1 wherein the first and second electrodes have a gap having a predetermined width therebetween, further including a second capacitor having a pair of electrodes having a gap therebetween smaller than the gap between the first and second electrodes, the gap width of the second capacitor being selected to allow flow of dielectric liquid therein but being small enough to significantly retain dielectric liquid in the gap of the second capacitor as the level of the dielectric liquid in the vessel falls below the level of the top of the second capacitor.

20. The sensor as set forth in claim 1 wherein the measuring means and the subtracting means are disposed in a monolithic integrated circuit having only passive external components.

21. The sensor is set forth in claim 1 further including means for compensating for variations in conductivity of the dielectric liquid.

22. The sensor as set forth in claim 1 further including means for keeping the capacitors whose capacitance is to be measured at the same voltage at all times.

23. The sensor as set forth in claim 1 wherein the subtracting means includes a differential current detector, the output of said detector being the difference between the currents flowing to the level detecting capacitor and to the reference capacitor.

24. The sensor as set forth in claim 23 further including means for generating an output voltage from the output of the detector, said output voltage being representative of the level of the dielectric liquid.

25. A sensor as set forth in claim 1 wherein said capacitance measuring means determines the time it takes each capacitor whose capacitance is to be measured to discharge below a reference level.

26. A sensor as set forth in claim 25 wherein the oscillator is a relaxation oscillator comprised of components having leakage current substantially lower than those of diodes and current sources under high temperatures.

27. A sensor as set forth in claim 25 wherein the capacitance measuring means includes a plurality of comparators having one input connected to a respective RC-network, each RC-network including a capacitor whose capacitance is being measured, and a second input connected to a voltage reference source, whereby in each cycle of the oscillator the output of each comparator is a pulse whose width is proportional to the respective capacitance being measured.

28. A sensor as set forth in claim 27 wherein each comparator is synchronized with the oscillator so that the output of each comaprator is unaffected by the charge on its respective capacitor during the charging portion of the waveform provided by said oscillator.

29. The sensor as set forth in claim 1 wherein the outputs of the capacitance measuring means are direct current voltages proportional to the capacitance of the capacitor being measured.

30. A sensor as set forth in claim 1, wherein said oscillator, capacitance measuring means, and substracting means includes components having leakage currents substantially lower than those of diodes and current sources under high temperature conditions, whereby the level of the dielectric liquid sensed by the sensor is relatively unaffected by the temperature of the liquid.

31. A sensor as set forth in claim 1, wherein the reference capacitor is closed so that its capacitance is independent of the level of the dielectric liquid.

5. The sensor as set forth in claim wherein the capacitance measuring means includes a plurality of comparators comprised of components having leakage currents substantially lower than those of diodes and current sources under high temperatures.

6. The sensor as set forth in claim 5 wherein one input of each comparator is connected to a respective RC-network, each RC-network including a capacitor whose capacitance is being measured, and the other input of each comparator is connected to a voltage reference course, whereby in each cycle of the oscillator the output of each comparator is a pulse whose width is proportional to the respective capacitance being measured.

7. The sensor as set forth in claim 6 wherein the output of each comparator is connected to a low pass filter so that the output of the capacitance measurement circuit is a direction current voltage proportional to the capacitance of the capacitor being measured.

8. The sensor as set forth in claim 6 wherein each comparator is synchronized with the oscillator so that the output of each comparator is unaffected by the charge on its respective capacitor during the charging portion of the waveform provided by said oscillator.

32. A sensor for sensing the level of a dielectric liquid such as oil, transmission fluid or the like comprising:

a sensor body adapted to be mounted with respect to a vessel containing the dielectric liquid whose level is to be measured;

a probe, including first and second electrodes forming a level detecting capacitor, said probe being secured to the sensor body and being adapted to be at least partially immersed in the liquid, when liquid is present, to detect the level of the liquid;

means for measuring the capacitance of the capacitor and for deriving from the capacitance measurement a signal representative of the level of the dielectric liquid at the sensor; and

said first and second electrodes being radially spaced apart and coaxial with each other, said second electrode being interior of the first, the spacing between the two electrodes forming at least two distinct regions and having at least two significantly different values as measured at different longitudinal positions along the probe so that the capacitance of the level detecting capacitor per unit length varies longitudinally along the probe, the spacing in one of the regions being sized so that the dielectric liquid in that region clings between the electrodes such that the liquid level in that region remains constant during normal operation of the probe irrespective of the level of the liquid, whereby the capacitance of that region is a function of the dielectric constant of the liquid rather than the level of the liquid.

33. The sensor as set forth in claim 32 wherein the sensor is particularly adapted for use with an internal combustion engine, a transmission or the like, said level detecting capacitor having a third distinct region adjacent the other regions and in which the spacing between the two electrodes is relatively small so that the third region is relatively sensitive to changes in the level of the dielectric liquid, said third region being disposed along the probe at a position at which the absence of oil or transmission fluid indicates a catastrophic loss of dielectric liquid.

34. The sensor as set forth in claim 33 including a fourth region, and wherein the spacing between the electrodes in two of the regions is substantially the same.

35. The sensor as set forth in claim 33 wherein the spacing between the electrodes is said one region is smaller than the spacing between the electrodes in any of the other regions.

36. A system for detecting the level of a dielectric liquid comprising:

a first capacitor having a pair of electrodes adapted to be disposed so that the dielectric liquid whose level is to be measured may flow between the electrodes, whereby the capacitance of the first capacitor varies with the level of the dielectric liquid;

a second capacitor so constructed and arranged that its capacitance is independent of the level of the dielectric liquid, said capacitance of the second capacitor being a reference generally equal to the capacitance of the first capacitor in air with no dielectric liquid present between its electrodes;

a third capacitor having a pair of electrodes adapted to be immersed in the electric liquid for detecting the dielectric constant thereof, whereby the capacitance of the third capacitor is a function of the dielectric constant of the liquid rather than of the level of the liquid;

a fourth capacitor so constructed and arranged that its capacitance is independent of the level of the dielectric liquid, said capacitance of the fourth capacitor being a reference generally equal to the capacitance of the third capacitor in air with no dielectric liquid between its electrodes;

means for applying a waveform to all four capacitors in such a manner that all four capacitors are at substantially the same instantaneous voltage during charging, so that the capacitance of each capacitor is directly reflected in the charging current flowing into that capacitors;

means for comparing the difference between the third and fourth capacitor charging currents to a reference, and for providing a comparing means output for controlling the output of the waveform applying means; and

output means responsive to the charging currents for generating an output signal representative of the level of the dielectric liquid.

37. The system as set forth in claim 36 wherein the waveform applying means includes four transistors, each being associated with its own one of the four capacitors, and an oscillator for supplying the waveform to simultaneously control the conduction of the four transistors so that the charging voltage applied to each capacitor is instantaneously the same.

38. The system as set forth in claim 37 further including means responsive to the charging currents to the third and fourth capacitors for detecting the difference in those two charging currents.

39. The system as set forth in claim 37 further including feedback means responsive to the charging currents to the third and fourth capacitors for controlling the output of the oscillator.

40. The system as set forth in claim 37 wherein the oscillator is a sawtooth oscillator.

41. The system as set forth in claim 36 wherein the output means includes a differential current detector effectively connected to the first and second capacitors for detecting the difference between the charging currents to the first and second capacitors.

42. The system as set forth in claim 36 further including self-test means for detecting a break in continuity of the circuit between the first or the third capacitors and their charging means.

43. The system as set forth in claim 36, further including self-test means for detecting a break in continuity of external circuitry connected to the system.

44. A system as set forth in claim 36 wherein the means for applying a waveform includes an oscillator for supplying a waveform output.

48. A system as set forth in claim 36 including a differential current detector for detecting the difference between the currents flowing to the level detecting first capacitor and the second capacitor.

49. A system as set forth in claim 48 further including a second differential current detector for detecting the difference between the currents flowing to the third capacitor and the fourth capacitor.

50. The system as set forth in claim 48 wherein the output of the differential current detector is a current, and further including means for converting said output of the detector to a filtered voltage to provide an output signal representative of the level of the dielectric liquid.

51. A system as set forth in claim 36 wherein the gap between the electrodes of the third capacitor is sized to provide significant clinging of the dielectric liquid between the electrodes when the level of liquid in the vessel falls below the level of the third capacitor.

45. A system as set forth in claim including a feedback loop from the third and fourth capacitor comparing means for controlling the rate of the oscillator.

46. A system as set forth in claim 45 wherein the means for comparing the difference between the third and fourth capacitor charging currents includes means for converting said difference to a voltage signal, and wherein said reference is a voltage reference.

47. A system as set forth in claim 46 wherein the feedback loop includes a transconductance amplifier which performs the comparison with the voltage reference, the output of the transconductance amplifier controlling the output of the oscillator for applying a time-varying waveform to the capacitors.

52. A system for detecting the level of a dielectric liquid comprising:

a level detecting capacitor having a pair of electrodes adapted to be disposed so that the dielectric liquid whose level is to be measured may flow between the electrodes, whereby the capacitance of the first capacitor varies with the level of the dielectric liquid;

a dielectric constant detecting capacitor having a pair of electrodes adapted to be immersed in the dielectric liquid for detecting the dielectric constant thereof, whereby the capacitance of the third capacitor is a function of the dielectric constant of the liquid rather than of the level of the liquid;

reference capacitor means for providing capacitance independent of the level of the dielectric liquid and substantially equal to the capacitance of said capacitors in air with no dielectric liquid between their electrodes;

means for applying a waveform to the capacitors and the reference capacitor means in such a manner that they are at substantially the same instantaneous voltage during charging, so that end capacitance is directly reflected in the charging current flowing into the respective capacitor or reference capacitor means;

means for comparing the difference between the charging currents of the dielectric constant detecting capacitor and the associated reference capacitor means to a reference, the output of the comparing means controlling the output of the waveform applying means; and

output means responsive to the charging currents for generating an output signal representative of the level of the dielectric liquid.

53. A sensor for sensing the level of a dielectric liquid in a vessel comprising:

a sensor body adapted to be mounted with respect to the vessel containing the dielectric liquid whose level is to be measured;

a probe including first and second electrodes forming a level detecting capacitor, said probe being secured to the sensor body and being adapted to be at least partially immersed in the liquid, when liquid is present, to detect the level of the liquid, the capacitance of the level detecting capacitor being a function of the level of the dielectric liquid in which said level detecting capacitor is immersed;

a reference capacitor disposed in said sensor body such that its capacitance is not affected by the presence or absence of the dielectric liquid, the capacitance of said reference capacitor being substantially the same as the capacitance of the level detecting capacitor when no dielectric liquid is present between the electrodes of the level detecting capacitor;

means for applying a waveform to each of said capacitors to charge the capacitors during a charging portion of each cycle of the waveform and to allow the capacitors to discharge during a second portion of each cycle;

capacitance measuring means for measuring the capacitance of each capacitor whose capacitance is to be measured, said measuring means providing an output signal having a parameter proportional to the measured capacitance of each capacitor and which signal is unaffected by the charge on each such capacitor during the charging portion of the waveform; and

subtracting means for effectively subtracting the signal parameter representing the capacitance of said reference capacitor with respect to the signal parameter presenting the capacitance of the level detecting capacitor to give a resulting signal representative of the level of the dielectrical liquid at the sensor.