Fluid level sensor systems and methods

• US 9,383,244 B2
• Filed: 10/25/2012
• Issued: 07/05/2016
• Est. Priority Date: 10/25/2012
• Status: Active Grant

• Current Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Original Assignee: Pentair Flow Technologies LLC (Pentair Plc (Ireland))
• Inventors: Bishop, Michael B., Boese, Thomas G.
• Primary Examiner(s): Jonaitis, Justin
• Assistant Examiner(s): NICHOLS, CHARLES W
• Application Number:
  US13/660,793
• Publication Number:
  US 20140119950A1
• Time in Patent Office: 1,349 Days
• Field of Search: 732/99, 417/36
• US Class Current: 1/1
• CPC Class Codes: F04D 15/0218 the condition being a liquid level or a lack of liquid supply
• CPC Class Codes: G01F 23/14 by measurement of pressure

Abstract

Fluid level sensor systems and methods can include an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space. An inner pressure tube can extend from the inner air space and through the sealed top. A contact sensor can be positioned near the sealed top, the contact sensor including a pair of contacts. A pair of conductors can extend from the contact sensor, one conductor extending from each one of the pair of contacts.

Claims

1. A fluid level sensor comprising:

an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space;

an inner pressure tube extending from the inner air space and through the sealed top;

an ambient pressure tube, an open end of the ambient pressure tube being positioned near the sealed top;

a pressure transducer connected to the inner pressure tube and the ambient pressure tube;

a contact sensor positioned near the sealed top, the contact sensor including a pair of contacts and a pair of conductors extending from the contact sensor, one conductor extending from each one of the pair of contacts; and

an over mold, the over mold encasing the inner pressure tube, the ambient pressure tube, the pair of conductors and the sealed top of the pressure cup, the over mold terminating at a first end of a protective bundle, the protective bundle enclosing the inner pressure tube, the ambient pressure tube, and the pair of conductors.

2. The fluid level sensor of claim 1, wherein the pair of contacts are positioned at an outer wall of the inverted cup.

3. The fluid level sensor of claim 2, wherein the pair of contacts are positioned at substantially opposite sides of the outer wall from each other.

4. The fluid level sensor of claim 1, wherein the open bottom is at an angle less than 90 degrees from a wall of the inverted cup, the open bottom including at least one gap in the wall of the inverted cup.

5. The fluid level sensor of claim 1, wherein a control circuit monitors the pair of conductors to detect when a fluid level has reached each one of the pair of contacts.

6. A fluid level sensor system comprising:

an inverted cup with a sealed top and an open bottom, the inverted cup defining an inner air space and having an inner pressure;

an inner pressure tube extending from the inner air space and through the sealed top, the inner pressure tube connected to a pressure line connector;

an ambient pressure tube including an open end, the open end being positioned near the sealed top, the ambient pressure tube connected to the pressure line connector;

a contact sensor positioned near the sealed top, the contact sensor including a pair of contacts and a pair of conductors extending from the contact sensor, one conductor extending from each one of the pair of contacts; and

an over mold, the over mold encasing the inner pressure tube, the ambient pressure tube, the pair of conductors and the sealed top of the pressure cup, the over mold terminating at a first end of a protective bundle, the protective bundle enclosing the inner pressure tube, the ambient pressure tube, and the pair of conductors, and terminating at a second end at the pressure line connector;

a control box to monitor the inner pressure from the inner pressure tube and the ambient pressure from the ambient pressure tube, the pressure line connector connectable to the control box; and

the control box including a pressure transducer and a switch, the pressure transducer to measure the inner pressure and the ambient pressure, and based upon the measured inner pressure and the measured ambient pressure, to activate the switch.

7. The system of claim 6, and further comprising a plug to connect the control box to a wall power.

8. The system of claim 6, and further comprising a power outlet, the power outlet to provide an operating power to a sump pump.

9. The system of claim 6, and further comprising a wireless controller in the control box, the wireless controller for transmitting and receiving data wirelessly for remote monitoring.

10. The system of claim 6, wherein the pair of conductors are connectable to the control box.