Method and apparatus for capacitive sensing the top level of a material in a vessel

• US 8,418,550 B2
• Filed: 12/22/2009
• Issued: 04/16/2013
• Est. Priority Date: 12/23/2008
• Status: Active Grant

• Current Assignee: Little Giant Pump Company
• Original Assignee: Little Giant Pump Company
• Inventors: Hampton, Steven W.
• Primary Examiner(s): Williams, Hezron E
• Assistant Examiner(s): Frank, Rodney T
• Application Number:
  US12/645,137
• Publication Number:
  US 20100154534A1
• Time in Patent Office: 1,211 Days
• Field of Search: 733/04.C, 732/90.R
• US Class Current: 73/304.C
• CPC Class Codes: G01F 23/265 for discrete levels
• CPC Class Codes: G01F 23/266 measuring circuits therefor
• CPC Class Codes: G01F 23/268 mounting arrangements of probes
• CPC Class Codes: G05D 9/00 Level control, e.g. controlling quantity of material stored in vessel
• CPC Class Codes: Y10T 137/0324 With control of flow by a condition or characteristic of a fluid

Abstract

A method and apparatus for sensing the top level of a material in a vessel is disclosed. A method and apparatus for sensing changes in the top level of a material in a vessel is disclosed.

Claims

1. A method of controlling a level of a material in a vessel, the method comprising the steps of:

placing at least two capacitive sensors proximate to the material in the vessel, a first capacitive sensor arranged to monitor a first range of levels in the vessel and a second capacitive sensor arranged to monitor at least a first level in the vessel, the first level being a part of the first range of levels;

monitoring an output of the first capacitive sensor;

monitoring an output of the second capacitive sensor; and

determining a current level of the material in the vessel based on the output of the first capacitive sensor and the output of the second capacitive sensor, the output of the second capacitive sensor being used to improve an accuracy of the determined current level.

2. The method of claim 1, wherein the first level is at an endpoint of the first range of levels.

3. The method of claim 1, wherein the first level is between a first endpoint and a second endpoint of the first range of levels.

4. The method of claim 1, further comprising the step automatically adjusting an amount of material in the vessel based on the current level when the current level corresponds to a control event.

5. The method of claim 4, wherein the amount of material in the vessel is reduced when the current level corresponds to the control event.

6. The method of claim 5, wherein a controller determines if the current level corresponds to the control event and in response thereto activates a material control device to reduce the amount of material in the vessel.

7. The method of claim 4, wherein the amount of material in the vessel is increased when the current level corresponds to the control event.

8. The method of claim 7, wherein a controller determines if the current level corresponds to the control event and in response thereto activates a material control device to increase the amount of material in the vessel.

9. The method of claim 1, wherein the material is flowable material.

10. The method of claim 1, wherein the material is fluid.

11. The method of claim 1, wherein a controller determines if the current level corresponds to an alarm event and in response thereto provides an indication to an alarm device.

12. The method of claim 1, wherein the controller includes an analog circuit and the step of monitoring an output of the first capacitive sensor includes the step of integrating a voltage associated with the first capacitive sensor over time.

13. The method of claim 1, wherein the controller includes an analog circuit and the step of monitoring an output of the second capacitive sensor includes the steps of integrating a voltage associated with the second capacitive sensor over time;

comparing the integrated voltage to a threshold voltage.

14. The method of claim 1, wherein the controller based on whether the integrated voltage crosses the threshold voltage determines a correction for a monitored voltage associated with the first capacitive sensor.

15. The method of claim 1, wherein the first range of levels is a variable range.

16. The method of claim 15, further comprising the step of setting an endpoint of the first range of levels based on at least one user input.

17. The method of claim 1, further comprising the steps of:

powering up a power circuit when the current level approaches a level corresponding to a control event; and

automatically adjusting an amount of material in the vessel based on the current level when the current level reaches the level corresponding to the control event.

18. The method of claim 1, further comprising the steps of:

automatically adjusting an amount of material in the vessel with a material control device based on the current level when the current level has moved in a first direction and corresponds to a control event;

determining if the current level continues to move in the first direction while the material control device is active; and

if the current level continues to move in the first direction provide an indication to an alarm device.

19. The method of claim 1, wherein the first range of levels includes a first end and a second end and the first level is spaced apart from the first end and the second end.

20. A method of controlling a level of a material in a vessel, the method comprising the steps of:

placing at least three capacitive sensors proximate to the material in the vessel, a first capacitive sensor arranged to monitor a first range of levels in the vessel, a second capacitive sensor arranged to monitor at least a first level in the vessel, the first level being a part of the first range of levels, and a third capacitive sensor arranged to monitor at least a second level in the vessel, the second level being a part of the first range of levels;

monitoring an output of the first capacitive sensor;

determining a level of the material based on the output of the first capacitive sensor;

monitoring an output of the second capacitive sensor when the determined level is proximate to the first level in the vessel;

monitoring an output of the third capacitive sensor when the determined level is proximate to the second level in the vessel; and

determining a current level of the material in the vessel based on the output of the first capacitive sensor and at least one of the output of the second capacitive sensor when the determined level is proximate to the first level in the vessel and the output of the third capacitive sensor when the determined level is proximate to the second level in the vessel, the output of the second capacitive sensor and the output of the third capacitive sensor being used to improve an accuracy of the determined current level.

21. The method of claim 20, further comprising the step automatically adjusting an amount of material in the vessel based on the current level when the current level corresponds to a control event.

22. The method of claim 20, wherein the first range of levels includes a first end and a second end and the first level is spaced apart from the first end and the second end.

23. An apparatus for controlling a level of a material in a vessel, the apparatus comprising:

a first capacitive sensor arranged to monitor a first range of levels in the vessel;

a second capacitive sensor arranged to monitor at least a first level in the vessel, the first level being a part of the first range of levels;

a controller operatively coupled to the first capacitive sensor and the second capacitive sensor; and

a material control device operatively coupled to the controller, the material control device having a first configuration wherein a fluid conduit external to the vessel is not in fluid communication with an interior of the vessel and a second configuration wherein the fluid conduit external to the vessel is in fluid communication with the interior of the vessel, the controller changing the configuration of the material control device based on an output of the first capacitive sensor and an output of the second capacitive sensor, the output of the second capacitive sensor being used to improve an accuracy of the determined current level.

24. The apparatus of claim 23, wherein the material control device removes material from the interior of the vessel in the second configuration.

25. The apparatus of claim 24, wherein the material control device is a pump.

26. The apparatus of claim 24, wherein the material control device is a valve.

27. The apparatus of claim 23, wherein the material control device adds material to the interior of the vessel in the second configuration.

28. The apparatus of claim 27, wherein the material control device is a valve.

29. The apparatus of claim 27, wherein the material control device is a pump.

30. The apparatus of claim 27, further comprising a non-capacitive sensor arranged to monitor at least a second level in the vessel, the second level being a part of the first range of levels.

31. The apparatus of claim 30, wherein the non-capacitive sensor is selected from the group of a mechanical float;

a heat sensor;

a conductive probe, and a pressure sensor.

32. The apparatus of claim 31, wherein the second level is spaced apart from the first level.

33. The apparatus of claim 31, wherein the second level is equal to the first level.

34. The method of claim 23, wherein the first range of levels includes a first end and a second end and the first level is spaced apart from the first end and the second end.