DESC:TECHNICAL FIELD
[001] The embodiments herein generally relate to liquid level sensing devices and more particularly, but not exclusively to an apparatus and a method to detect liquid level in a compressed air source of a pneumatic system.

BACKGROUND
[002] Generally, air dryers are used to remove water vapour from compressed air and inline filters are used to remove particulates such as dust, dirt, oil and other deposits from compressed air to prevent pressure built up in the lines or pipes. Air dryers and inline filters are commonly used in various industries such as automotive industry, etc. and also in commercial applications. However, water molecules in their vapor state are small enough to flow through most air dryers and filters. The presence of water vapour will lead to the formation of rust and scale in the air piping system and thereby resulting in equipment failure or device failure or system failure. Further, air dryers and inline filters will fail to operate due overloaded liquid contamination therein. Further, water can back up into the compressor and results in the compressor failure or machinery or system failure. Furthermore, the volume of condensation in the system will vary with changes in weather conditions. Hence, the water level in compressed air in air dryer or inline filter or any other air system is detected and then water vapour is taken out of the corresponding pneumatic devices or system by using appropriate or corresponding instruments or devices.
[003] In conventional practice, the water level in compressed air in air dryers, inline filters and any other pneumatic system is detected by using dew point sensors. However, dew point sensors have low response time, lower reliability of the reading and sensor failure due to exposure of oil and water condensation. Another conventional practice to detect water level in compressed air is done by using chilled mirrors. The chilled mirrors detect and indicate accurate water level readings in compressed air. However, the chilled mirrors are complex in design, expensive and frequent maintenance is required due to accumulation of dirt, oil, dust and other contaminants.
[004] Therefore, there exists a need for an apparatus and a method to detect liquid level in a compressed air source of a pneumatic system. Furthermore, there exists a need for a simple apparatus to detect liquid level in a compressed air source which eliminates the aforementioned drawbacks.

OBJECTS
[005] The principal object of the embodiments of this invention is to provide an apparatus to detect liquid level in compressed air source of a pneumatic system.
[006] Another object of the embodiments of this invention is to provide a reliable and durable apparatus to detect liquid level in compressed air source of a pneumatic system.
[007] Yet another object of the embodiments of this invention is to provide a simple and cost-effective apparatus to detect and indicate liquid level in compressed air source of a pneumatic system.
[008] A further object of the embodiments of this invention is to provide an apparatus for easier removal of the liquid from a pneumatic system.
[009] Still, another object of the embodiments of this invention is to provide a method of providing an apparatus for detecting liquid level in a compressed air source of a pneumatic system.
[0010] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0012] FIG. 1 depicts a schematic diagram of an apparatus to detect liquid level in compressed air source of a pneumatic system, according to an embodiment of the invention as disclosed herein;
[0013] FIG. 2 depicts a perspective view of an apparatus to detect liquid level in compressed air source of a pneumatic system, according to an embodiment of the invention as disclosed herein; and
[0014] FIG. 3 depicts a flowchart of a method of providing an apparatus for detecting liquid level in a compressed air source of a pneumatic system, according to an embodiment of the invention as disclosed herein.

DETAILED DESCRIPTION
[0015] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0016] The embodiments herein achieve an apparatus to detect liquid level in compressed air source of a pneumatic system. Further, embodiments herein achieve a method of providing an apparatus for detecting liquid level in a compressed air source of a pneumatic system. Referring now to the drawings, and more particularly to FIGS. 1 through 3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0017] FIG. 1 depicts a schematic diagram of an apparatus to detect liquid level in compressed air source of a pneumatic system, according to an embodiment of the invention as disclosed herein. In an embodiment, the apparatus 100 includes compressed air source (not shown), a housing 102, an internal cavity 104, a hollow tube 106, at least one moisture sensor 108, a controller unit 110, an output device 112, a signal conditioner 114, a reference data 116, a comparator unit 118, a power supply unit 120, and a cylindrical member 122.
[0018] In an embodiment, the apparatus includes housing 102. In an embodiment, the housing 102 is made of rigid material and having a cylindrical shape as shown in FIG. 2. However, it is also within the scope of the invention that the housing 102 may be made from any type of metals or materials and have any desired shape without otherwise deterring the intended function of providing an enclosure as can be deduced from this description and corresponding drawings.
[0019] In an embodiment, the housing 102 encloses a cylindrical member 122. In an embodiment, the cylindrical member 122 defines the internal cavity 104. In an embodiment, the hollow tube 106 is attached to the housing 102. In an embodiment, the housing 102 is provided with an opening to attach with the hollow tube 106. In an embodiment, the hollow tube 106 is in fluid communication with the compressed air source (not shown). In an embodiment, the compressed air flows into the hollow tube 106 thereby to the internal cavity 104 of the housing 102.
[0020] In an embodiment, the apparatus 100 includes the at least one moisture sensor 108 to detect the liquid level in the compressed air source. In an embodiment, the at least one moisture sensor 108 located within the internal cavity 104. In an embodiment, the at least one moisture sensor 108 is provided in fluid communication with the compressed air source. In an embodiment, the at least one moisture sensor 108 includes at least one electrode (not shown) to detect the liquid level in the compressed air source. In an embodiment, the at least one moisture sensor 108 includes at least two separate electrodes enclosed in cylindrical member 122. In an embodiment, the cylindrical member 122 is configured to collect the liquid from the compressed air source. In an embodiment, the at least one moisture sensor 108 generates at least one electrical signal to indicate the liquid level in the compressed air source.
[0021] In an embodiment, the apparatus 100 includes the controller unit 110. In an embodiment, the controller unit 110 is provided in electronic communication with the at least one moisture sensor 108. In an embodiment, the controller unit 110 is configured to generate at least one output signal in response to the at least signal received from the moisture sensor 108.
[0022] In an embodiment, the controller unit 110 includes a signal conditioner 114. In an embodiment, the signal conditioner 114 is configured to process the at least one signal generated by the at last one moisture sensor 108 and convert the processed signal into at least one digital value.
[0023] In an embodiment, the controller unit 110 further includes a reference data 116 which includes a predetermined acceptable value of liquid level for the pneumatic system. The reference data 116 is stored in the memory of the controller unit 110.
[0024] In an embodiment, the controller unit 110 further includes a comparator unit 118 configured to compare the processed signal of the at least one moisture sensor 108 with the reference data 116 stored in the controller unit 110 to indicate the liquid level in the internal cavity 104. In an embodiment, the controller unit 110 is connected to the power supply 120.
[0025] In an embodiment, the apparatus 100 includes the output device 112. In an embodiment, the output device 112 is provided in electronic communication with the controller unit 110 to provide an indication to an operator about presence of liquid in the compressed air source in response to the at least one signal from the moisture sensor 108. In an embodiment, the output device 112 is configured to provide visual indication of data indicating that liquid level in the internal cavity 104 is in excess of a predetermined level. In an embodiment, the output device 112 is configured to provide an alarm indicating that liquid level in the internal cavity 104 is in excess of a predetermined level. In an embodiment, the output device 112 is configured to change color in accordance with the liquid levels in the compressed air source. In an embodiment, the output unit changes from white to red to indicate the liquid level in the compressed air source.
[0026] In an embodiment, a method 200 of providing an apparatus for detecting liquid level in a compressed air source of a pneumatic system is disclosed in the FIG. 3. Accordingly the method includes steps of, providing a housing 102 having a cylindrical member 122 which includes an internal cavity 104 (step 202). Further, the method includes, connecting a hollow tube 106 to the housing 102 (step 204). The hollow tube 106 being in fluid communication with the compressed air source, whereby compressed air flows into the hollow tube 106 thereby to the internal cavity 104 of the housing 102. Furthermore, the method includes, providing at least one moisture sensor 108 located within the internal cavity 104 and in fluid communication with the compressed air source (step 206). The at least one moisture sensor 108 is configured to generate at least one signal in response to the liquid level in the compressed air source. In addition, the method includes, providing a controller unit 110 in electronic communication with the at least one moisture sensor 108 (step 208). The controller unit 110 is configured to generate at least one output signal in response to the at least signal received from the moisture sensor 108. Also, the method includes, providing an output device 112 in electronic communication with the controller unit 110 to provide an indication to an operator about presence of liquid in the compressed air source in response to the at least one signal from the moisture sensor 108 (step 210).
[0027] In an embodiment, the liquid level in the compressed air source is measured continuously and can be stored and used at any time. In an embodiment, the apparatus 100 is installed at least one of the locations such as incoming pneumatic system on machine or at end of a compressed air line.
[0028] The technical advantages provided by the embodiment herein detection of moisture in compressed air, visual display to indicate the volume of condensation liquid and easy removal of condense liquid.
[0029] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Referral numerals:
Apparatus 100
housing 102
Internal cavity 104
Hollow tube 106
Moisture sensor 108
Controller unit 110
Output device 112
Signal conditioner 114
Reference data 116
Comparator unit 118
Power supply unit 120
Cylindrical member 122
,CLAIMS:CLAIMS
We claim,
1. An apparatus 100 for detecting liquid level in a compressed air source of a pneumatic system, said apparatus 100 comprising:
a housing 102 having a cylindrical member 122 which includes an internal cavity 104;
a hollow tube 106 connected to the housing 102; wherein the hollow tube 106 being in fluid communication with the compressed air source, whereby compressed air flows into the hollow tube 106 thereby to the internal cavity 104 of the housing 102;
at least one moisture sensor 108 located within the internal cavity 104 and in fluid communication with the compressed air source, wherein the at least one moisture sensor 108 is configured to generate at least one signal in response to the liquid level in the compressed air source;
a controller unit 110 in electronic communication with the at least one moisture sensor 108, wherein the controller unit 110 is configured to generate at least one output signal in response to the at least signal received from the moisture sensor 108; and
an output device 112 in electronic communication with the controller unit 110 to provide an indication to an operator about presence of liquid in the compressed air source in response to the at least one signal from the moisture sensor 108.
2. The apparatus as claimed in claim 1, wherein the output device 112 is configured to provide visual indication of data indicating that liquid level in the internal cavity 104 is in excess of a predetermined level.

3. The apparatus as claimed in claim 1, wherein the output device 112 is configured to provide an alarm indicating that liquid level in the internal cavity 104 is in excess of a predetermined level.

4. The apparatus as claimed in claim 1, wherein the controller unit 110 includes a signal conditioner 114 to process the at least one signal generated by the at last one moisture sensor 108 and convert the processed signal into at least one digital value.

5. The apparatus as claimed in claim 1, wherein the controller unit 110 further includes a reference data 116 which includes a predetermined acceptable value of liquid level for the pneumatic system.

6. The apparatus as claimed in claim 1, wherein the controller unit 110 includes a comparator unit 118 configured to compare the processed signal of the at least one moisture sensor 108 with the reference data 116 stored in the controller unit 110 to indicate the liquid level in the internal cavity 104.
7. The apparatus as claimed in claim 1, wherein the cylindrical member 122 is configured to collect the liquid from the compressed air source.

8. The apparatus as claimed in claim 1, wherein the at least one moisture sensor 108 includes at least one electrode to sense the liquid level in the compressed air source.

9. The apparatus as claimed in claim 1, wherein the apparatus is connected to a power supply unit 120.

10. A method 200 of providing an apparatus 100 for detecting liquid level in a compressed air source of a pneumatic system, said method comprising steps of:
providing a housing 102 having a cylindrical member 122 which includes an internal cavity 104;
connecting a hollow tube 106 to the housing 102; wherein the hollow tube 106 being in fluid communication with the compressed air source, whereby compressed air flows into the hollow tube 106 thereby to the internal cavity 104 of the housing 102;
providing at least one moisture sensor 108 located within the internal cavity 104 and in fluid communication with the compressed air source, wherein the at least one moisture sensor 108 is configured to generate at least one signal in response to the liquid level in the compressed air source;
providing a controller unit 110 in electronic communication with the at least one moisture sensor 108, wherein the controller unit 110 is configured to generate at least one output signal in response to the at least signal received from the moisture sensor 108; and
providing an output device 112 in electronic communication with the controller unit 110 to provide an indication to an operator about presence of liquid in the compressed air source in response to the at least one signal from the moisture sensor 108.