CA2010392A1 - Fluid level sensor and controller - Google Patents

Fluid level sensor and controller

Info

Publication number
CA2010392A1
CA2010392A1 CA002010392A CA2010392A CA2010392A1 CA 2010392 A1 CA2010392 A1 CA 2010392A1 CA 002010392 A CA002010392 A CA 002010392A CA 2010392 A CA2010392 A CA 2010392A CA 2010392 A1 CA2010392 A1 CA 2010392A1
Authority
CA
Canada
Prior art keywords
plates
recited
liquid
container
plate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002010392A
Other languages
French (fr)
Inventor
Joseph R. Adamski
Donald A. Coates
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Raytheon Co
Original Assignee
Raytheon Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Raytheon Co filed Critical Raytheon Co
Publication of CA2010392A1 publication Critical patent/CA2010392A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F39/00Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00 
    • D06F39/08Liquid supply or discharge arrangements
    • D06F39/087Water level measuring or regulating devices
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01FMEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
    • G01F23/00Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
    • G01F23/22Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
    • G01F23/26Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields
    • G01F23/263Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields by measuring variations in capacitance of capacitors
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01FMEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
    • G01F23/00Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
    • G01F23/22Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
    • G01F23/26Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields
    • G01F23/263Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields by measuring variations in capacitance of capacitors
    • G01F23/266Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields by measuring variations in capacitance of capacitors measuring circuits therefor
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01FMEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
    • G01F23/00Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
    • G01F23/22Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
    • G01F23/26Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields
    • G01F23/263Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields by measuring variations in capacitance of capacitors
    • G01F23/268Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring variations of capacity or inductance of capacitors or inductors arising from the presence of liquid or fluent solid material in the electric or electromagnetic fields by measuring variations in capacitance of capacitors mounting arrangements of probes
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05DSYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D9/00Level control, e.g. controlling quantity of material stored in vessel
    • G05D9/12Level control, e.g. controlling quantity of material stored in vessel characterised by the use of electric means
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T137/00Fluid handling
    • Y10T137/7287Liquid level responsive or maintaining systems
    • Y10T137/729Washing machine cycle control

Abstract

Abstract of the Disclosure A fluid level sensor for determining the amount of liquid in a container. Thin metal plates are placed parallely adjacent each other to form a capacitor cell coated with a non-hygroscopic film. The plates are mounted on the walls of the container containing fluid. As the fluid covers more surface area of the capacitor plates, the dielectric properties of the fluid increase the capacitance of the cell proportionally. The plates are connected to an oscillator whose output frequency varies with the change in container fluid levels. By monitoring these frequency changes, the container fluid levels of the fluid in the container can be controlled.

Description

~03~2 :

FLUID LEVEL SENSOR AND CONTROLLER
Background of the Invention The present invention relates to a fluid level sensor and controller, and more particularly relates to an improved apparatus for measuring, detecting, and controlling liquid levels within a washing machine.
Liquid level sensors for washing machines currently in use comprises two tubes. Each tube having one end connected to the bottom of the washing machine tub and the other end connected to a pressure sensitive switch. The first switch actuates a valve that controls the flow of water going into the washing machine. The second switch when depressed ~ -actuates a pump to drain water from the washing machine. As ~ ~
, the water level within the washing machine increases, the water within each tube increases, causing the net air pressure over atmospheric pressure to push against the pressure sensitive switch. When the water level in the first tube rises so that the air pressure reaches a set value, the sensing switch toggles and the water flow into the machine is -~ `-shut off. To drain water from the machine, a pump is turned on. As the water drains, the air pressure in the second tube drops, depressing ithe~isecond sensing switch, causing!a signal to be sent to turn off the pump. By turning the water going ; into the washing machine and the drain pump off and on, the ~ 25 level within the washing machine can be set.

~: :
2~3g2 One problem with this liquid level sensor is that the switch is mechanical and may wear out with use. A mechanical sensor may leak air pressure over time if allowed to remain pressurized. This can cause flooding and subsequent water damage. Another drawback is that the pressure sensitive switch may not have the sensitivity to set the water level with accuracy. Furthermore, the second pressure sensation may not be able to detect when presure in the second tube is below atmospheric level. Accordingly, the second switch depresses when water is still present in the tub. Conse-quently, the pump must continue to drain water from the tub for a time period thereafter. Further, this liquid level sensor requires mechanical parts which may be expensive to use and assemble. This liquid level sensor also does not 15- cohtinuously signal the liquid level to a controller but nstead indicates only a preset level.
Other methods to sense the liquid level in a tub ~- include a capacitance liquid level sensor. A typical cap-acitance liquid level sensor comprises a metal rod coated with an insulating material such as Teflon, forming one electrode of a capacitor and a tub wall forming a second ;;~
electrode of the capacitor. A signal with appropriate RF
oscillation is applied across the two electrodes so as to be able to detect and amplify changes in capacitance.
These changes provide an output that indicates the liquid ;~

, ~ .

~ 2~0~2 level or provides an alarm if the liquid level exceeds a predetermined threshold.
This arrangement suffers from various drawbacks. For example, this arrangement can only be used in tubs which are made of conductive material. Otherwise, additional capacitive elements would have to be provided. This arrange-ment has further drawbacks in that when used with liquids that contain sticky materials, a build-up on the wires or rods occurs, which results in an inaccurate output indi-cation.
Another liquid level sensor is described in U. S.
Patent No. 4,122,718. A pair of wires are encased in ;~ Teelon or an equivalent material. The wires are placed parallel to each other and are spaced equidistantly therein IS with the Teflon material closed at the terminating end of the liquid level sensor. One drawback of this arrangement is that when the wires are used in a turbulent tub to maintain a constant spacing between the wires, they must be installed within a tube made from a rigid material. A
further drawback of this invention is that soap or film may form on the wires and this can possibly affect the capaci-tance and oscillation 'frequency of the seosor. A further drawback is that wires do not provide enough surface area to get an accurate capacitance without the addition of more -complicated circuitry. This drawback may prevent the -2~03~2 indicator from sensing liquid levels down to such small amounts as 1/4 of an inch.
Another drawback of capacitance sensors is that they can be effected by noise and stray capacitance. The cap-acitor sensor is typically located in the washing machine tub and wired to the capacitance sensing circuitry located a few feet away. The capacitance of the wires changes during washing machine operation as the tub vibrates, resulting in the wires moving around. Accordingly, the sensing circuitry is susceptible to the stray capacitance of the wires between the capacitor sensor and the sensing circuitry. Further, due to the noise generated by the washing machine motor, the output signal of the capacitance -circuitry can qive erroneous data. Accordingly, due to the noise of the washer motor and turbulence caused by the w~sher agitator, the accuracy and stability of the sensing ~;~
apparatus can be affected.

~ , _ 4 _ 2~03~2 Summary of the Invention It is an object of the present invention to provide an improved fluid level sensor and controller.
It is another object of the invention to provide a fluid level sensor and controller having simple construction and thus offering easy installation, maintenance, high-reliability, and high-speed response.
It is further an object of the invention to provide a liquid level sensor with improved performance in a washing machine container where the liquid has high turhulence.
It is also an object of this invention to provide a '~ liquid level sensor that has minimal susceptibility to film -~ or other materials that are used in a washing machine.
It is an additional object of this liquid level sensor to provide an apparatus that can detect level changes of less than 1/4 of an inch.
It is another object of the present invention to provide~a liquid level sensing apparatus and controller -~
that changes the amount of liquid in the container where the sensor is located in response to the changes of capacitance between the probes of the sensor.
; ~
It is an additional object of the present invention to ~ provide a liquid level sensor that is small enough to be ?,'` used in a washing machine.
~;~ 25 These and other objects of the invention are obtained Z~)~03~2 generally by providing an apparatus for sensing the level of liquid in a container comprising first and second parallel metal plates having opposingly facing flat surfaces, means for supporting the plates inside the container, spacing means, attached to the first and second plates for maintaining a constant spacing between the first and second plates, and a capacitance sensing means coupled to the plates for generating a signal indicating the level of liquid in the container. It may be preferable that the sensing appar atus further comprise a coating means for encasing the metal plates and having a thickness of less than 1/8 of an inch to prevent soap film from adhering to the sensor. It ; may also be preferabIe that the capacitance sensing means be attached to the top of the first and second plates to 15~ reduce sensitivity to stray noise and capacitance. It is further preferable that the capacitance sensing means ~-comprises a means for generating a frequiency proportional to the level of the liguid in the container to track the amount of liquid in the container without complicated circuitry. It is further preferable that the plates be spaced close enough to each other so as to provide a pre-determined sensjitivity; and spaced far enough away from each other so that any film from the liquid is prevented from being clogged between the plates.
The invention may further be practiced by a capacitive ~ ;

- 6 - ~

2~392 probe for sensing the level of liquid within a washing machine tub comprising a first and second parallel metal plate having opposingly facing flat surfaces having constant spacing of less than 1/2 inch, means for supporting the plates within the washing machine tub, a corrosive resistive material encasing the first and second parallel metal plate having a thickness of less than 1/8 of an inch. The capaci-tive probe also comprises an insulating spacing means attached between the first and second plate for maintaining a constant spacing between the first and second plates and a capacitive sensing means attached to the first and second plates for generating a frequency proportional to the level of liquid in the container. It may be preferable that the plate is coated with a Teflon material having a thickness less than l/lOOth inches so that the Teflon materials dielectric strength has little effect of the total capaci-tance of the capacitive probe.
The invention may also be practiced by the method of sensing liquid flowing into a washing machine comprising the steps of positioning a first and second parallel metal plate having opposingly facing flat surfaces in substan-tially vertical position within the liquid within the machine, encasing the plates in a non-corrosive material, maintaining a constant spacing between the first and second plates of less than 1/2 inch, sensing the capacitance between ''' ~ ' the first and second plate and generating a frequency signal ;~
proportional to the level of liquid in the container in response to the capacitance sensed. It may be preferable that the method further comprise the step of changing the flow of liquid into the washing machine in response to the frequency signal. It may also be preferable that the method further comprise the steps of positioning a circuit board on the metal plate the contains circuitry that senses the capacitance between the first and second plate, and gener-ates the frequency signal. It is further preferable that the method further comprise the step of maintaining a constant spacing between the first and second plate to prevent a film within the liquid from becoming clogged within the plates. It is also preferable that the method further comprise the steps of determining the time period ; ~ of the frequency signal, comparing the time period to a pre-stored value, and changing the flow of liquid into the washing machine in response to the comparison.

; :,' Y.,, ~

,., :-~ 25 2~LG3~2 ~rief Description of the Drawings FIG. 1 shows a diagrammatic view of a washing machine ~ -showing a preferred embodiment of the present invention;
FIG. 2 shows a perspective view of the sensing apparatus shown in FIG. 1 FIG. 3 shows a sectioned perspective view of the probe for the sensing apparatus shown in FIG. 2;
FIG. 4 shows a circuit diagram of the frequency generating circuitry built into the fluid level sensing apparatus shown in FIG. 2;
FIG. 5 shows a line graph of the frequency period versus fluid height for the frequency generating circuitry;
FIG. 6 shows frequency signals from the frequency generation circuitry for a washing machine having a high -lS llqu;id level and low liquid level, and FIG. 7 shows a sectional view of an alternate embodi~
ment of the liquid level sensor shown in FIG. 1.

: .

:.

: ' ~''.`'~'', ~- _ g _ :- ~ ~ , '.: ' ~:

~0392 Description of the Preferred Embodiment In the embodiment of the present invention shown in FIG. 1, an automatic washing machine 10 is shown having a water containing tub 12 electrically connected to ground, a clothes containing basket 14 mounted for rotation about a vertical axis, and an agitator 16 mounted centrally within the basket 14 for oscillation about the vertical axis. An electric motor 18 is arranged to drive selectively the basket 14 or the agitator 16 through a transmission 20.
Water or liquid 22 is delivered to the tub 12 from hot and cold water supply pipes 24 and 26 through a mixing and shut-off valve 28. Soap suds or film 23 is generated : during operation from detergent added at the beginning of ;
the wash cycle. Valve 28 is actuated electrically through : 15 a solenoid means 32 and 34. A drain 36 is arranged at the bottom of tub 12. Drain 36 is connected to pump 38 that ; removes water from tub 12 through pipe 40.
An associated block diagram indicates that the elec~
tronic level control is provided which includes a frequency ~ ~ `
generation circuitry 42, a flow and timer control circuit 44, and a level selector 46 which can be adjusted to set the point at which thelcontrol circuit 44 enables solenoids 32 . -, ~ . .
: and 34 and pump 38 to turn on. The frequency generation ~ circuitry 42 is connected to a liquid level sensor or probe :~
;~ 25 48 in the form of two cold rolled steel plates 50 and 52 , ~''~'`,.;' ~V~392 (see FIG. 2) being coated with a corrosion resistive material 54 and being separated by a non-conductive material or spacers 56 and 58. The liquid level sensor 48 is disposed vertically between the substantially vertical wall Gf the tub 12 and the substantially vertical wall of the basket 14. The liquid level sensor 48 is used in conjunction with the liquid 22 in tub 12 to provide a capacitance to the frequency generation circuitry 42. The capacitance between the plates 50 and 52 of the liquid level sensor 48 will be equal to: ~ ~
C = KA/D -where; :
K equals the dielectric constant of the materials between the plates;
; 15 A equals the area of the plates; and D equals the distance between the plates.
Thus, the capacitance between the plates 50 and 52 is a direct : function of the dielectric constant K of the material between the two plates SO and 52. As the depth or the level of liquid 22 in the tub 12 changes, a greater or lesser portion of the liquid level sensor 48 will have the higher dielectric constant of the;liquidj 22 between the plates 50 and 52 than -will the portion above the liquid which is surrounded by air 53 (water has a dielectric constant of 81 as compared to air, which has a dielectric constant of 1, thus resulting ~ ~

- 1 1 - ~ `

2~1~03~2 in a significant difference in capacitance). As will be explained later, the effect of the coating 54 on the total capacitance is insignificant. As a result, the capacitance of the liquid level sensor 48 changes with a change in the liquid level, resulting in the frequency signal generated by the frequency generation circuitry 42 varying essentially linerally depending on the depth of the water or other liquid 22 in the tub 12 (see FIG. 5).
FIGS. 2 and 3 illustrate the liquid level sensor 48 that is shown in FIG. 1. The liquid level sensor 48 is vertically mounted to tub 12 with bracket 49. The sensor 48 contains first and second plates 50 and 52 separated by spacers 56 - -r and 58. The spacers 56 and 58 can be constructed from any non-conducting material, but preferably has a high dielectric strength and is made from a ridged ceramic material. Con-necting first plate 50 to ceramic spacers 56 and 58 and second plate 52 are screws 60, 62 and nuts 64, 66. Screws ; ~;
60, 62 and nuts 64, 66 are preferably made from an insulating material such as plastic. Screw 60 is positioned near the ~-~
top of liquid level sensor 48 and screw 62 is located near the bottom of liquid level sensor 48. Plates 50 and 52 each contain three holes~ 68, 70, 72; holes 70 and 72 for ~ M
insertion of plastic screws 60 and 62 while hole 68 is for insertion a rivet 74. `~
Mounted on top of first and second plates 50 and 52 is ~ '.''.

20~03~2 circuit board 76. Mounted on circuit board 76 is frequency generation circuitry 42 including LM555 timer 78 and assoc-iated circuitry 96, 100 and 106 (shown in FIG. 4~. Rivets 74 are driven through the circuit board 76 into the rivet hole 68 on the top of first and second plates 5Q and 52. ---The rivets 74 provide an electrical contact for connecting -~
the first and second plates 50 and 52 directly to circuit board 76. By riveting the circuit board 76 to first and second plates 50 and 52, the distance between the level sensor 48 and the frequency generation circuitry 42 is small. Further, there are no wires connecting the level sensor 48 to the frequency generation circuitry 42, which can move during washing machine 10 operation. Accordingly, the stray capacitance between the first and second plates :: :
50 and 52 and circuit ~oard 76 is minimized. Further, the ~- noise within the washing machine tub 12 caused by both the agitator 16 and the electric motor 18, coupling into the frequency generation circuitry 42 and flow and timer control ~;
- -circuitry 44 is insignificant with respect to the frequency `
signal. Wire or line 84 connects circuit board 76 to the flow and timer control circuitry 44 located within the washing machine chlassi~s (not shown). Vcc wire 86 anq ground wire 88 connect to a power supply (not shown) within the washing machine chassis.
The first and second plates 50 and 52 are coated with : ~:

as;~

a non-corrosive material 54. One such material is a fluoro- ~ , plastic such as polytetrafluoroethylene (sold under the trademark "Teflon" by Dupont) or a modified ETFE (such as ~TEFZEL~ also sold by Dupont). The preferable thickness of this coating 54 is .0005 inches. The dielectric constant of the coating is approximately 2. Accordingly, the dielec-tric constant and total thickness are small enough so as not to affect the capacitance between the first and second plates 50 and 52. The coating 54 thickness is large enough to prevent corrosion of the metal plates 50 and 52 and to prevent soap film 23 from adhering to the metal plates 50 and 52. ~ , When assembiing the liquid level sensor 48, it is preferable that the ceramic spacers 56 and 58 maintain a ; 15 dis~tance between plates 50 and 52 o~ less than 1/2 inch.
The ideal plate separation is between 1/16 and 1/8 of an ~,,~,;,-inch. It is recognized that having the distance between the plates 50 and 52 greater than 1/16 of an inch, soap ,~
film 23 from the liquid 22 in the washing machine tub 12 is ~, .
prevented from collecting on the plates 50 and 52. If soap film 23 were to collect between the plates 50 and 52, the capacitance betlween the,plates SQ and 52 could change., It `
is also recognized that by keeping the distance between the plates 50 and 52 less than 1/2 inch, the frequency gener~
ation circuitry 42 provides a signal to the flow and timer ~

- 14 - , ~ :
:. ~.-' 20103512 :
, .. . .

control circuitry 44 that varies linearly with the liquid ~-22 in the tub 12 without being affected by the soap film 23. It is further recognized that keeping the distance (D) between the plates 50 and 52, small, liquid level sensor 48 maintains a sufficiently large sensor capacitance such that the dielectric caused by the soap film 23 is insignificant with respect to air and water.
The plates 50 and 52 are preferably 1/2 inch wide, having a thickness of 1/50 to 1/10 of an inch. These plates dimensions enable the liquid level sensor 48 to to fit within a standard washing machine tub 12. The preferred length of the plates 50 and 52 is 15 inches with a 1/2 inch - ;
lip at the top. It is recognized that by having the plates ~ 50 and 52 made from steel and being substantially rigid, ;~
`~ I5 the turbulence due to the water flowing in the washing ~;
machine tub 12 has little affect of the constant spacing between the plates 50 and 52. This further increases the ~-sensitivity of the liquid level sensor 48. ;~
It is further recognized that by maintaining the con~
stant distance between the first and second plates 50 and 52 and coating the plates with a thin flouroplastic material such as~Teflon 90,, the liquid level sensor 48 capacitance remains substantially linear during washing machine operation. `
-~ Referring to FIG. 4, there is shown a schematic of the frequency generation circuitry 42 which generates a frequency ~ ;

signal having a period proportional to the capacitance between the first and second plates 50 and 52, and the flow and timer control circuitry 44. Frequency generation circuitry 42 contains a LM555 Timer 78, manufactured by National Semiconductor Corporation of Santa Clara, Calif-ornia. Further information on the LM555 timer 78 chip is located in the National Semiconductor Corporation Linear -~
Data Book, ~1982 which is hereby incorporated by reference.
Flow and timer control circuitry 44 contains a microprocessor ~ ~
122 such as a 68HCll, manufactured by Motorola Semiconductor ~ -of Austin, Texas.
~; Both frequency generation circuitry 42 and flow and timer control circuitry 44 are powered by a five volt power ~; ~ supply (not shown). Connected between the five volt power `; ~ 15 line (vcc ? 86 and the DIS (Discharge) pin 94 of the LM555 ;~ ;
Tlmer 78 is resistor 96, here having 500K ohms resistance.
Connected across the DIS pin 94 and the THR (Threshold) pin 98 of the LM555 Timer 78 is reslstor 100, here having 62K
ohms resistance. The THR pin 98 is connected to the TR*
(Trigger) pin 102. Connected to THR pin 98 is plate 52 of the liquid level sensor 48. Plate 50 of the liquid level ~sensor 48~is connected~ to`GND. The CV (Control Voltage) ~ ;
pln 104 of the LM555 Timer 78 is tied through or .01 F
capacitor 106 to ground. The Reset pin 108 is tied to the ~ ` -Vcc line 86.

During operation, the LM555 timer 78 operates with well known principles and sets the freguency at its output in accordance with the capacitance between THR 98 and GND.
Accordingly, LM555 timer 78 generates a frequency signal S onto line 84 which varies proportionately to changes in the liquid level sensor 98 capacitance. Furthermore, the frequency signal will change with the fluid height in tub 12. Frequency generation circuitry 42 transmits the fre-quency signal through line 84 to flow and timer control circuitry 44. It is recognized that the frequency signal varies between GND and Vcc (typically 5V) and the noise coupled to the frequency signal is typically around 100 mV.
Hence, the frequency signal is substantially immune from -~
noise from the washing machine motor 18.
I-n FIG. 5, there is shown a graph of the frequency period of the frequency signal as a function of the fluid helght in the tub 12. Point 138 indicates the relationship between the fluid height and the frequency signal period when the tub 12 is full and point 140 indicates the rela- --~
tionship when the tub 12 is empty.
In FIG. 6, there is shown a frequency signal 110 corres-ponding to aniemptiy tub and a frequency signal 112 corres-ponding to a full tub. As the fluid 22 level increases in tub 12, the period of the frequency signal decreases. It is recognized that the frequency signal varies linearly -~ 20~0392 with the level of the fluid 22 in the tub 12. The period of the frequency signal may be adjusted by changing the resistance on resistor 96.
The Flow and Timer control circuitry 44 is connected -to the Frequency Generation circuitry 42 through line 84, the level selector 46 through line 114, the hot and cold solenoids 32 and 34 through respective lines 116 and 118, and the drain pump 38 through line 120. Within the Flow and Timer control circuitry 44 is a microprocessor 122 and its associated circuit (not shown). The microprocessor 122 is connected to level selector 46 through line 114. Level selector 46 generates a signal onto line 114 having a value corresponding to a selected liquid level.
During washing machine operation, the microprocessor ~ ~ 15 122 enables solenoid means 32 and 34 to allow water to fill ! tub 12. The microprocessor 122 then determines when the -~
liquid level has reached a preset height in tub 12 by -sampling frequency signal on line 84, such as frequency ~-signal 110. Rising edge 126 of frequency signal 110 indi-cates to the microprocessor 122 to start an internal timer (not shown). When the microprocessor 122 detects second rising edge 128, the microprocessor then reads the timer and compares the edge time (corresponding to the time between rising edges) to a value from the level selector 46. When the edge time is greater than or equal to the 20103~312 value from the level selector 46 (see point 138, FIG. 5), microprocessor 122 sends a signal to solenoids through line 116 and 118 to actuate solenoid means 32 and 34 to stop the liquid from entering the tub 12. Microprocessor 122 can also continuo~'sly send the sensed level data to a display or dis-play controller (not shown) via data lines 146 to indicate to the operator the water level in the tub. This display may be an LED or LCD type that is well known. It is recog-nized by continuously monitoring the capacitance of sensor 48 as the liquid in the tub 12 is added or drained, an accurate level of li'quld is the tub can be diplayed at all times.
To drain liquid from the tub 12, the microprocessor 122 sends a signal through line 120 to turn on pump 38. Pump ;~ 38 then drains liquid from tub 12 through drain 36. The ~, microprocessor 122 then samples the frequency signal such as frequency slgnal 112 and determines the time between ' ~' rising edges 132 and 134. When the time between rising `~
edges 132 and 134 is less than a pre-stored value (see point ; 140, FIG. S), corresponding to time between frequency '--~ signal rising edges when no fluid is present in tub 12, the microprocessor 122 sends a signal through line 120 to turn off pump 38. This opération may'be repeated throughout the wash cycle.
Referring to FIG. 7, there is shown an alternate embodi-ment of the liquid level sensor 48a vertically mounted - 19 - ' 2t)1039~ ~

between tank 12 and basket 14 with mounting bracket 49a.
Liquid level sensor 48a includes a printed circuit board 144 having a plate or metal strip SOa on the surface of one side and a plate or metal strip 52a on the surface of the other side of circuit board 144. Metal strips 50a and 52a and printed circuit board 144 are coated with a non-corrosive material 54a such as Teflon to prevent any soap film 23 from liquid 22 from attaching to liquid level sensor 48a.
The liquid level sensor preferably has dimensions of 15"
high x 1.5" wide x 1/2" thick.
Mounted near the top of liquid level sensor and connected to metal strips 50a and 52a is frequency genera-tion circuitry 42. Metal strip 50a is connected through control circuitry 44 on circuit board 144 to GND. Power (5V) is provided to control circuitry 44 on circuit board 144 from a power supply (not shown) located in the washing machine chassis. The output of frequency generation cir-cuitry 42 is connected through line 84 to flow and timer control circuitry 44. During operation, the average dielec-tric constant around metal strips 50a and 52a changes as the liquid 22 level in the tub 12 rises and falls. This change in dielectric oonstant results in the frequency signal from frequency generation circuitry 42 to change its period. Flow and timer control circuitry 44 responds to the changes in the frequency signal as previously described.

20103~2 .

It is recognized that the capacitance of the metal strips 50a and 52a can vary by changing the average dielectric con-stant due to the level of the liquid around the metal strips and not changing the dielectric constant of the - 5 material between the metal strips. It is further recognized by coating the strips with a non-stick, a non-porous and a non-corrosive material 54a such as Teflon or fluoroplastic, the sensor 48a capacitance is impervious to soap film 23.
This concludes the Description of the Preferred Embodi-ments. A reading of those skilled in the art will bring to ~
mind many modifications and alternatives without departing ~-from the spirit and scope of the invention. Accordingly, it is intended that the invention only be limited by the following claims. ~-~

~ ~ , ~ -~ :; '

Claims (24)

What is claimed is:
1. An apparatus for sensing the level of liquid in a container comprising:
first and second parallel metal plates having opposingly facing flat surfaces;
means for supporting said plates inside said container;
spacing means, attached to said first and second plate for maintaining a constant spacing between said first and second plates; and a capacitive sensing means coupled to said plates for generating a signal indicating the level of liquid in said container.
2. The apparatus as recited in Claim 1 wherein each of said first and second plates has a front surface, a back surface, and side surfaces, said front surface of said first plate facing said back of surface of said second plate.
3. The apparatus as recited in Claim 2 wherein said front and back surfaces are wider than said side surface.
4. The apparatus as recited in Claim 1 further com-prising a coating means for encasing said metal plates, said coating means having a thickness of less than 1/8 of an inch.
5. The apparatus as recited in Claim 1 further com-prising means for supporting said first and second plates in a vertical position within said container.
6. The apparatus as recited in Claim 1 wherein said capacitance sensing means is attached to the top of said first and second plates.
7. The apparatus as recited in Claim 1 wherein said capacitive sensing means comprises a means for generating a signal having a frequency proportional to the level of the liquid in the container.
8. The apparatus as recited in Claim 1 further com-prising means, responsive to said capacitive sensing means for adjusting the water level within said container.
9. The apparatus as recited in Claim 1 wherein said first and second plates are spaced close enough to each other so as to provide a predetermined sensitivity and spaced far enough away from each other so that film from said liquid is prevented from being clogged between said plates.
10. A capacitive probe for sensing the level of liquid within a washing machine tub comprising:

first and second parallel metal plates having opposingly facing flat surfaces having constant spacing of less than 1/2 inch;
means for supporting said plates within said washing machine tub;
a corrosion resistant material encasing said first and second parallel metal plate having a thickness less than 1/8";
an insulating spacing means attached between said first and second plate for maintaining a constant spacing between said first and second plates; and a capacitive sensing means attached to said first and second plates for generating a frequency proportional to the level of liquid in said container.
11. The capacitive probe recited in Claim 10 wherein said spacing is between .05 and .2 inches.
12. The capacitive probe recited in Claim 10 wherein said plate is coated with a Teflon material having a thickness less than 1/100 inches.
13. The capacitive probe recited in Claim 10 wherein said sensing means is mounted on a printed circuit board.
14. The capacitive probe recited in Claim 10 wherein said plate is shaped to support said circuit board.
15. The capacitive probe recited in Claim 10 wherein said plate is mounted within said container 50 as to contact said liquid.
16. The capacitive probe as recited in Claim 10 further comprising means for displaying the level of liquid in said container in response to said frequency.
17. The method of sensing liquid flowing into in a washing machine comprising the steps of:
positioning a first and second parallel metal plate having opposingly facing flat surfaces in a substantially vertical position within the liquid within said machine;
encasing said plates in a non-corrosive material;
maintaining a constant spacing between said first and second plate of less than 1/2 inch;
sensing the capacitance between the first and second plate; and generating a frequency signal proportional to the level of liquid in said container in response to the capacitance sensed.
18. The method as recited in Claim 17 further com-prising the step of changing the flow of liquid into said washing machine in response to said frequency signal.
19. The method as recited in Claim 17 further com-prising the steps of positioning a circuit board on said metal plate that contains circuitry that senses the capaci-tance between said first and second plate and generates said frequency signal.
20. The method as recited in Claim 17 wherein said first and second plates have a width between 3/8 and 5/8 inches and a coating having thickness less than .1 inches.
21. The method as recited in Claim 17 further com-prising the step of maintaining a constant spacing between said first and second plate to prevent a film within said liquid from becoming clogged between said plates.
22. The method as recited in Claim 17 further com-prising the step of controlling the flow of liquid into said machine in response to said frequency signal.
23. The apparatus as recited in Claim 17 further com-prising the steps of:
determining a time period of said frequency signal;

comparing said time period to a pre-stored value; and changing the flow of liquid into said washing machine in response to said comparison.
24. The apparatus as recited in Claim 17 further com-prising the step of displaying the changes of the level of liquid in said tube in response to said frequency signal.
CA002010392A 1989-03-06 1990-02-20 Fluid level sensor and controller Abandoned CA2010392A1 (en)

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AU5004690A (en) 1990-09-06
GB9005027D0 (en) 1990-05-02
DE4006998A1 (en) 1990-11-22
GB2230100A (en) 1990-10-10

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