Resistance-based level detection device

Abstract

A resistance-based level detection device is provided. A resistance-based level detection device according to an embodiment of the present invention comprises: a pair of electrode detection members installed in a storage container, wherein a material having a length-dependent resistance value is used for at least one of the electrode detection members; and a control unit for supplying electricity to the pair of electrode detection members and converting an electrical characteristic value, measured using a current generated between the pair of electrode detection members by a stored material, into the height of the material. The control unit predicts the usage amount or usage pattern of the stored material, calculates an alarm or the timing for replenishing the stored material, or provides information to a communication unit to enable remote monitoring and control.

Description

Resistance-based level detection device

[0001] The present invention relates to a resistance-based level detection device, and more particularly, to a resistance-based level detection device having a structure in which an electrode detection member utilizing a material having a characteristic of having a resistance value that varies depending on the length detects an electrical characteristic value that varies depending on the amount of various substances in a storage container, thereby determining the amount of the substance and accurately and stably detecting the level.

[0002]

[0003] In industrial settings, accurately assessing the storage levels of various materials is crucial. Real-time monitoring of ice storage levels in ice machines, fuel levels in fuel storage tanks, grain storage levels in grain silos, and chemical solution levels in chemical storage tanks is essential to determine the appropriate replenishment time.

[0004] Conventional material level detection methods primarily used mechanical sensors or floating gauges. In particular, in the case of ice makers, the conventional full-ice detection lever method can sometimes fail to perform mechanical functions, such as when the lever's rotating section freezes.

[0005] Additionally, in the case of liquid storage tanks, floating gauges may malfunction or corrode due to changes in viscosity or temperature, and in the case of solid particle storage tanks, mechanical sensors may be damaged or clogged due to impact from particles.

[0006] Therefore, there is a need for a device with a universal structure that can accurately and stably detect the levels of various substances.

[0007]

[0008] In order to solve the problems of the prior art as described above, one embodiment of the present invention provides a resistance-based level detection device capable of detecting the height and amount of material, and prediction, alarm, and remote monitoring by detecting an electrical characteristic value that varies depending on the amount of material in a storage container using an electrode detection member whose resistance value varies depending on the length.

[0009]

[0010] According to one aspect of the present invention for solving the above-mentioned problem, there is provided a resistance-based level detection device, comprising: a pair of electrode detection members installed in a storage container, at least one of which utilizes a material having a characteristic in which a resistance value varies depending on a length; and a control unit that supplies electricity to the pair of electrode detection members and converts an electrical characteristic value measured by current conduction by a material stored between the pair of electrode detection members into a height of the material; wherein the control unit predicts the amount or use pattern of the stored material, calculates a replenishment time or an alarm for the stored material, or provides information to a communication unit so as to enable monitoring and control from a remote location.

[0011] In one embodiment, the control unit may include a correction algorithm that calculates the height of a material by correcting for differences in electrical characteristics depending on the type of stored material.

[0012] In one embodiment, the control unit may further calculate information on whether the storage container is full, the amount of available material, and the replenishment time based on the height of the produced material, and provide the calculated information to the display unit.

[0013] In one embodiment, the control unit learns the usage pattern of the stored material to predict the replenishment time, and can enable remote monitoring and control through the communication unit.

[0014] In one embodiment, the electrode sensing member may have different resistance values ​​in the upper, middle, and lower portions.

[0015] In one embodiment, when the stored material is ice or conductive solid particles, the electrode sensing member can calculate the height of the stored solid particles by using a change in resistance value according to the accumulation state of the solid particles.

[0016] In one embodiment, when the stored material is a liquid, the control unit can calculate the height and volume of the liquid by correcting in real time changes in electrical characteristics according to the temperature, concentration, and ion concentration of the liquid.

[0017] In one embodiment, when the stored material is a solid particle having electrical conductivity, a dispersing member may be further included in the storage container so that the solid particles are evenly distributed within the storage container.

[0018] In one embodiment, the storage vessel may be at least one of an ice storage tank, a liquid storage tank, a solid particle storage tank, a slurry storage tank, and a gel storage vessel.

[0019]

[0020] A resistance-based level detection device according to one embodiment of the present invention can continuously and precisely detect the height of various substances in a storage container by utilizing an electrode detection member whose resistance value varies depending on its length and changes in the electrical characteristics of the stored substance.

[0021] In addition, a resistance-based level detection device according to one embodiment of the present invention can predict the amount and usage pattern of a material based on the measured resistance value, and calculate a replenishment time or an alarm, thereby realizing efficient inventory management and automated maintenance.

[0022] In addition, a resistance-based level detection device according to one embodiment of the present invention can enable real-time remote management and implementation of a smart factory by monitoring and controlling a storage state remotely through a communication unit.

[0023] In addition, a resistance-based level detection device according to one embodiment of the present invention can maintain reliable level detection even under various environmental conditions by applying a correction algorithm according to material-specific characteristics such as temperature, concentration, and particle size.

[0024] In addition, the resistance-based level detection device according to one embodiment of the present invention can dramatically improve the efficiency and safety of storage management in various industrial fields such as energy, chemistry, food, and environment by overcoming the limitations of existing mechanical detection methods.

[0025]

[0026] FIG. 1 is a configuration diagram of a resistance-based level detection device according to one embodiment of the present invention applied to an ice maker.

[0027] FIG. 2 is a detailed block diagram of a control unit that applies a resistance-based level detection device according to one embodiment of the present invention to an ice maker.

[0028] FIG. 3 is a detailed configuration diagram showing the upper, middle, and lower parts of an electrode sensing member applied to an ice maker using a resistance-based level sensing device according to one embodiment of the present invention.

[0029] FIG. 4 is a drawing for explaining a method of detecting the amount of ice by applying a resistance-based level detection device according to one embodiment of the present invention to an ice maker.

[0030] FIG. 5 is a schematic diagram illustrating a method for detecting full ice by applying a resistance-based level detection device according to one embodiment of the present invention to an ice maker.

[0031] FIG. 6 is a general configuration diagram of a resistance-based level detection device according to one embodiment of the present invention.

[0032] FIG. 7 is a detailed block diagram of an extended control unit in a resistance-based level detection device according to one embodiment of the present invention.

[0033] FIG. 8 is a configuration diagram of a resistance-based level detection device applied to a liquid storage container according to one embodiment of the present invention.

[0034] FIG. 9 is a configuration diagram of a resistance-based level detection device applied to a solid particle storage container according to one embodiment of the present invention.

[0035] FIG. 10 is a drawing showing an example of application of electrically conductive materials in a resistance-based level detection device according to one embodiment of the present invention.

[0036] FIG. 11 is an expanded block diagram of an intelligent control system in a resistance-based level detection device according to one embodiment of the present invention.

[0037]

[0038] Hereinafter, with reference to the attached drawings, embodiments of the present invention will be described in detail so that those skilled in the art can easily practice the present invention. The present invention may be implemented in various different forms and is not limited to the embodiments described herein. In the drawings, parts irrelevant to the description have been omitted for clarity of description, and the same reference numerals designate identical or similar components throughout the specification.

[0039] Hereinafter, a resistance-based level detection device according to one embodiment of the present invention will be described in more detail with reference to the drawings.

[0040] FIG. 1 is a block diagram of a resistance-based level detection device applied to an ice maker according to one embodiment of the present invention, and FIG. 2 is a detailed block diagram of a control unit applied to an ice maker according to one embodiment of the present invention.

[0041] Referring to FIGS. 1 and 2, an embodiment (100) of applying a resistance-based level detection device according to one embodiment of the present invention to an ice maker may include an electrode detection member (110), a control unit (120), and a display unit (130).

[0042] This embodiment (100) is equipped with an electrode sensing member (110) that utilizes a material having a characteristic in which the resistance value changes depending on the length, thereby enabling detection of electrical characteristic values ​​that change depending on the amount of material accumulated in the storage container (10).

[0043] The control unit (120) is connected to a pair of electrode sensing members (110) to detect the amount of ice and whether it is full and calculate the amount of usable ice and the time for replenishing ice, and the display unit (130) can display whether it is full and the amount of usable ice and the time for replenishing ice.

[0044] The present embodiment (100) may be equipped with a storage container (10). The storage container (10) is a container for storing ice produced by an ice maker, and may generally have a rectangular parallelepiped or cylindrical structure. The storage container (10) has a configuration capable of accommodating ice, may have a predetermined capacity, and may be configured to be installed in a conventional ice maker such as a refrigerator.

[0045] The storage container (10) may include an elastic member (101). The elastic member (101) is provided on both sides of the storage container (10) and can push the ice from both sides so that the ice is not piled up unevenly but is densely stacked without any empty space. The elastic member (101) is made of a spring or elastic rubber material so that the ice is not piled up unevenly to one side but is evenly distributed around the electrode sensing member (110). This structure plays an important role in increasing the accuracy of resistance measurement.

[0046] The electrode sensing member (110) may be installed in the storage container (10). In addition, at least one electrode sensing member (110) may be provided using a material having a characteristic in which the resistance value varies depending on the length (distance).

[0047] The electrode sensing member (110) can be installed vertically in the storage container (10). The electrode sensing member (110) can have upper, middle, and lower portions each made of different resistors, and can have a resistance value that increases from the upper portion to the lower portion. Specifically, the upper portion has a resistance value of 10Ω to 10KΩ, the middle portion has a resistance value of 10KΩ to 1MΩ, and the lower portion has a resistance value of 1MΩ to 100MΩ.

[0048] The electrode sensing member (110) has a rod shape with a predetermined diameter and length, and may be composed of a first electrode sensing member (110-1) on one side that functions as a (+) terminal and a second electrode sensing member (110-2) on the other side that functions as a (-) terminal. A pair of electrode sensing members (110) may generally be installed in parallel and spaced apart from each other by a distance of 5-20 mm.

[0049] The control unit (120) is communicatively connected to the electrode sensing member (110) and the display unit (130) to control the overall operation of the present embodiment (100). The control unit (120) may include a power supply unit (121), an ice quantity calculation unit (122), a usable amount prediction unit (123), an ice replenishment time prediction unit (124), and an ice full detection unit (125).

[0050] The power supply unit (121) can supply power to a pair of electrode sensing members (110). The power supply unit (121) can supply DC power. For example, the power supply unit (121) can supply a positive voltage (+) to the first electrode sensing member (110-1) and a negative voltage (-) to the second electrode sensing member (110-2). The supply voltage is generally set in the range of 5 V to 24 V, and a low voltage can be used for safety reasons.

[0051] The ice quantity calculation unit (122) can calculate the amount of ice from information such as measured current or resistance. Specifically, the ice quantity calculation unit (122) can calculate the amount of ice by detecting that the electrical characteristic values ​​measured between the electrode detection members (110) change according to the amount of ice being made and accumulated in the storage container (10).

[0052] The current supplied from the power supply unit (121) can form a path that flows from the first electrode sensing member (110-1) to the second electrode sensing member (110-2) through the surface of the ice accumulated in the storage container (10). At this time, the current flows by selecting the shortest path with the lowest resistance according to the basic laws of physics, so the current mainly flows at a height corresponding to the level at which the ice is accumulated.

[0053] As the ice level increases, current flows through the upper section of the electrode sensing member (110). The upper section has a relatively low resistance value, allowing the current to flow easily. Conversely, as the ice level decreases, current flows through the lower section. The lower section has a relatively high resistance value, allowing the current to flow more slowly.

[0054] The control unit (120) can measure the current flowing between the electrode sensing members (110) in real time. The measurement circuit is composed of a constant current source and a voltage measuring unit, and can calculate the resistance value using the following formula according to Ohm's law:

[0055] R_total = V_measured / I_constant

[0056] Here, R_total is the total circuit resistance, V_measured is the measured voltage, and I_constant is the supply current.

[0057] The usable amount prediction unit (123) can predict information about the amount of ice that can be used thereafter based on information about the amount of ice calculated by the ice amount calculation unit (122). Specifically, the usable amount prediction unit (123) can compare the consumed amount of ice and the remaining amount after providing ice once from the highest ice height, and can calculate the amount of ice that can be used thereafter based on the remaining amount of ice based on the comparison information. Although the amount of ice used varies depending on the user, the usable amount prediction unit (123) can calculate the amount of ice that can be used thereafter based on a certain amount of ice through programmed repetitive learning.

[0058] The ice replenishment time prediction unit (124) can predict information about the ice replenishment time based on information about the amount of ice calculated by the ice quantity calculation unit (122) and the usable amount prediction unit (123) and the amount of ice that can be used thereafter.

[0059] The full ice detection unit (125) can determine whether the storage container (10) is full of ice. For example, the full ice detection unit (125) can determine whether the storage container (10) is full of ice by comparing whether the amount of ice calculated by the ice amount calculation unit (122) corresponds to a preset full ice amount. As another example, the full ice detection unit (125) can determine whether the storage container (10) is full of ice by using electrode plates (140) installed above and below the storage container (10), as described below.

[0060] At this time, the control unit (120) may be configured as a programmed PLC (Programmable Logic Controller) assembly, and may provide information on the amount of ice calculated by the ice amount calculation unit (122), whether the ice is full detected by the ice full detection unit (125), and information on the amount of ice available thereafter and the time for replenishing ice to the display unit (130).

[0061] The display unit (130) can display information provided by the control unit (120) regarding whether the ice is full, the amount of ice available thereafter, and the time for replenishing ice so that the user can check. Here, the display unit (130) can be equipped with a separate display module, and can utilize a display module mounted on a conventional ice maker such as a refrigerator.

[0062] FIG. 3 is a detailed configuration diagram showing the upper, middle, and lower parts of an electrode sensing member applied to an ice maker using a resistance-based level sensing device according to one embodiment of the present invention.

[0063] Referring to FIG. 3, the electrode sensing member (110) according to one embodiment of the present invention may have different electrical resistances in the upper part (111), the middle part (112), and the lower part (113).

[0064] The electrode sensing member (110) may have resistance values ​​of 10Ω to 10KΩ, 10KΩ to 1MΩ, and 1MΩ to 100MΩ at the upper portion (111), middle portion (112), and lower portion (113), respectively. At this time, the electrode sensing member (110) may be designed such that the resistance value increases stepwise in the longitudinal direction. This may be to optimize the current change according to the change in ice level.

[0065] The electrode sensing member (110) may be composed of a first electrode sensing member (110-1) on one side that functions as a (+) terminal and a second electrode sensing member (110-2) on the other side that functions as a (-) terminal. A pair of electrode sensing members (110) may be installed to be spaced apart from each other by a distance of 5-20 mm, and may form a rod shape having a predetermined diameter and length.

[0066] When the electrode sensing member (110) has a resistance of less than 10Ω, it may cause excessive current changes, and when it has a resistance of more than 100MΩ, it may cause minimal current changes, which may lower the detection accuracy. Therefore, when the electrode sensing member (110) has a resistance of 10Ω to 100MΩ, it is easy to measure changes in electrical characteristics according to the amount of ice, which may improve the accuracy of full ice detection.

[0067] The resistance-based level detection mechanism of the present invention can operate according to Ohm's law (V=IR). The current applied from the power supply unit (121) can flow from the first electrode detection member (110-1) to the second electrode detection member (110-2) along the surface of the ice stacked in the storage container (10). At this time, the ice acts as a conductor, and the current can flow along the path with the lowest resistance in the section corresponding to the height of the ice.

[0068] When the ice level is high, the current mainly passes through the upper section (111) of the electrode sensing member, so a relatively high current can be measured due to the low resistance value of this section. When the ice level is medium, the current passes through the middle section (112), so an intermediate resistance value is applied, so the measured current can also show an intermediate value. On the other hand, when the ice level is low, the current passes through the high resistance section of the lower section (113), so the measured current can be greatly reduced as the resistance value increases.

[0069] Based on this principle, the control unit (120) can quantitatively determine the amount of ice based on the current value measured in each section of the electrode sensing member (110). In addition, both pairs of electrodes may be composed of a material whose resistance value varies with length, or, if necessary, only one side may be equipped with an electrode having variable resistance characteristics and the other side may be replaced with a general conductive material.

[0070] In this way, the resistance-based level detection device (200) according to one embodiment of the present invention can continuously and precisely detect the height of various substances in a storage container by utilizing an electrode detection member whose resistance value varies depending on its length and changes in the electrical characteristics of the stored substance.

[0071] FIG. 4 is a drawing for explaining a method of detecting the amount of ice by applying a resistance-based level detection device according to one embodiment of the present invention to an ice maker.

[0072] Referring to FIG. 4, the ice fullness detection device of an ice maker according to one embodiment of the present invention can detect (a) when the amount of ice is full, (b) when the amount of ice is about half of the storage container (10), (c) when the amount of ice is small, and (d) when ice needs to be replenished.

[0073] A pair of electrode sensing members (110) can detect the amount of ice by detecting electrical characteristic values ​​that change depending on the amount of ice accumulated in the storage container (10).

[0074] First, when the amount of ice is relatively large, as in (a), the current can flow along a relatively short path through the first electrode sensing member (110-1), the surface of the ice stacked up to the upper side, and the second electrode sensing member (110-2). At this time, since the pair of electrode sensing members (110) have relatively small resistance, the control unit (120) can measure a relatively high current between the first electrode sensing member (110-1) and the second electrode sensing member (110-2).

[0075] Next, when the amount of ice is about half of the storage container (10), as in (b), the current can flow along a relatively longer path than (a) through the first electrode sensing member (110-1) and the surface of the ice stacked in the middle and the second electrode sensing member (110-2). At this time, since the pair of electrode sensing members (110) has a relatively greater resistance than (a), the control unit (120) can measure a relatively lower current than (a) between the first electrode sensing member (110-1) and the second electrode sensing member (110-2).

[0076] Next, when the amount of ice is small, as in (c), the current can flow along a relatively long path between the first electrode sensing member (110-1) and the surface of the stacked ice and the second electrode sensing member (110-2). At this time, since the pair of electrode sensing members (110) have relatively large resistance, the control unit (120) can measure a relatively low current between the first electrode sensing member (110-1) and the second electrode sensing member (110-2).

[0077] Next, in case where the amount of ice is small and replenishment is required, as in (d), no current flows because the ice does not come into contact between the first electrode sensing member (110-1) and the second electrode sensing member (110-2). Accordingly, the control unit (120) can determine that replenishment of ice is required and control the display unit (130) to display this.

[0078] Meanwhile, even when the amount of ice accumulated in the storage container (10) is at a similar level, the current flowing between the first electrode sensing member (110-1) and the surface of the accumulated ice and the second electrode sensing member (110-2) may deviate depending on the shape of the ice stack. In other words, the value of the flowing current may deviate depending on how densely the ice is arranged between the electrode sensing members (110).

[0079] Accordingly, the control unit (120) can detect the amount of ice by calculating the range of the deviation that occurred and determining the height of ice accumulation in each of sections (a), (b), and (c). Since the upper portion (111) of the electrode sensing member (110) can have an electric resistance of 10Ω to 10KΩ, the control unit (120) can obtain the current value when the upper portion (111) of the electrode sensing member (110) has an electric resistance of 10Ω and the current value when the upper portion (111) of the electrode sensing member (110) has an electric resistance of 10KΩ, thereby calculating the range of current values ​​that can be measured when the amount of ice is relatively large.

[0080] In addition, the control unit (120) can obtain the current value when the middle part (112) of the electrode sensing member (110) has an electrical resistance of 10KΩ and the current value when the middle part (112) has an electrical resistance of 1MΩ, thereby calculating the range of current values ​​that can be measured when the amount of ice is in the middle of the storage container (10).

[0081] In addition, the control unit (120) can calculate the range of current values ​​that can be measured when the amount of ice is small by obtaining the current value when the lower part (113) of the electrode sensing member (110) has an electrical resistance of 1 MΩ and the current value when the lower part (113) has an electrical resistance of 100 MΩ.

[0082] That is, the control unit (120) can calculate the range of deviation that may occur by obtaining the minimum and maximum values ​​of the current that can be measured at each of the upper (111), middle (112) and lower (113) portions of the electrode sensing member (110).

[0083] FIG. 5 is a schematic diagram illustrating a method for detecting full ice by applying a resistance-based level detection device according to one embodiment of the present invention to an ice maker.

[0084] Referring to FIG. 5, an embodiment (100) of applying a resistance-based level detection device to an ice maker may further include a pair of electrode plates (140) installed horizontally in a storage container (10).

[0085] The electrode plate (140) may be composed of a first electrode plate on one side that functions as a (+) terminal and a second electrode plate on the other side that functions as a (-) terminal. One of the electrode plates (140) may be provided on the bottom of the storage container (10), and the other electrode plate (140) may be provided on the upper side of the storage container (10), but may be provided at a position corresponding to the full ice.

[0086] At this time, the full ice detection unit (125) of the control unit (120) can detect the full ice by using the current flowing between the electrode plate (140) provided at the bottom of the storage container (10) and the electrode plate (140) provided at a position corresponding to the full ice. That is, when ice accumulates in the storage container (10) and comes into contact between the electrode plates (140), the full ice detection unit (125) can detect the full ice by the current flowing in the electrode plates (140). Here, when the amount of ice is small, the electrode plate (140) is in an open state and no current flows, so the full ice detection unit (125) can determine that the ice is not full. Thereafter, the control unit (120) can provide the detected full ice status to the display unit (130).

[0087] FIG. 6 is a general configuration diagram of a resistance-based level detection device according to one embodiment of the present invention.

[0088] Referring to FIG. 6, a resistance-based level detection device (200) according to one embodiment of the present invention may include an electrode detection member (210), a control unit (220), and a display unit (230).

[0089] The resistance-based level detection device (200) is a general-purpose system that can be applied to level detection of various conductive materials beyond ice makers. In this case, the electrically conductive material may be a solid, liquid, slurry, gel, etc.

[0090] The storage container (20) may be at least one of an ice storage tank, a liquid storage tank, a solid particle storage tank, a slurry storage tank, and a gel storage container. The storage container (20) can accommodate various substances such as liquids, slurries, and conductive solids, and may be implemented in various shapes such as a cylindrical shape, a rectangular parallelepiped shape, and a hopper shape.

[0091] The electrode sensing member (210) is installed vertically inside the storage container (20) and may be composed of a pair of a first electrode sensing member (210-1) and a second electrode sensing member (210-2). The pair of electrode sensing members (210) may be installed spaced apart from each other by a predetermined interval. In addition, at least one electrode sensing member (210) may be provided using a material having a characteristic in which the resistance value varies depending on the length (distance). For example, the upper part of the electrode sensing member (210) may be designed to have a resistance value of 10Ω to 10KΩ, the middle part may be designed to have a resistance value of 10KΩ to 1MΩ, and the lower part may be designed to have a resistance value of 1MΩ to 100MΩ.

[0092] The control unit (220) supplies power to the electrode sensing member (210) and measures the current flowing or voltage generated between the two electrodes to calculate the height (level) of the material in the storage container. The display unit (230) can visually provide the calculated level information to the user.

[0093] A resistance-based level detection device (200) can measure the level by utilizing the distribution of resistance and the conductivity of a material. When a conductive material is filled in the storage container (20), the material can form an electrical path between the electrode detection members (210-1, 210-2). As the height of the material increases, current flows to the upper section with a low resistance value, and conversely, as the height of the material decreases, current flows only through the lower section with a high resistance value, so the resistance of the entire circuit can increase.

[0094] The control unit (220) can detect electrical characteristic values ​​measured in each section in real time and quantitatively calculate the height of the stored material. Here, the electrical characteristic values ​​may be resistance, current, voltage, etc.

[0095] In this way, the resistance-based level detection device (200) according to one embodiment of the present invention can realize efficient inventory management and automated maintenance by predicting the amount and usage pattern of a material based on the measured resistance value and calculating a replenishment time or alarm.

[0096] FIG. 7 is a detailed block diagram of an extended control unit in a resistance-based level detection device according to one embodiment of the present invention.

[0097] Referring to FIG. 7, the control unit (220) may include a power supply unit (221), a material amount calculation unit (222), a density correction unit (223), an environment correction unit (224), and a prediction unit (225).

[0098] The power supply unit (221) can stably supply a constant voltage or current to the electrode sensing member (210). The power supply unit (221) can selectively use DC or AC power. The power supply unit (221) can automatically adjust the supply parameters according to the characteristics of the material to be measured. For example, the power supply unit (221) can optimize the supply parameters according to the conductivity or resistance distribution of the material.

[0099] The power supply unit (221) can minimize errors caused by external noise and power fluctuations by incorporating constant voltage and constant current circuits and a filter circuit. Furthermore, the power supply unit (221) includes an automatic diagnostic function, enabling it to output an alarm signal or safely shut down the system in the event of an abnormality such as overvoltage or a short circuit. At this time, the power supply unit (221) can apply a high-precision resistance measurement circuit such as a Wheatstone bridge.

[0100] The material amount calculating unit (222) can measure electrical characteristic values ​​such as resistance, current, and voltage between the electrode sensing members (210-1, 210-2) in real time. The material amount calculating unit (222) can calculate the height (level) of the material in the storage container (20) based on the measured values. For example, the material amount calculating unit (222) can calculate the resistance value using Ohm's law (V=IR), and can convert it into a quantitative level (height) by comparing it with the resistance values ​​of each section of the upper, middle, and lower parts of the electrode sensing member (210).

[0101] That is, the material quantity calculation unit (222) may be capable of calculating levels by interval or continuously. At this time, the material quantity calculation unit (222) may process a signal converted by an ADC (analog-to-digital converter) in a microcontroller, etc. In addition, the material quantity calculation unit (222) may increase accuracy by incorporating a noise filtering and nonlinearity correction algorithm of the measurement signal.

[0102] The density correction unit (223) can correct the output value by reflecting the type and density change of the stored material. In the case of liquid, the density correction unit (223) can correct the density change according to temperature in real time. In the case of solid particles, the density correction unit (223) can perform correction considering particle size, filling ratio, compressibility, etc. At this time, the density correction unit (223) can dynamically update the correction coefficient by linking with external sensors such as a temperature sensor, a pressure sensor, and a humidity sensor. In addition, the density correction unit (223) can be applied to various field environments by embedding a density correction table or correction formula for each material.

[0103] The environmental compensation unit (224) can compensate for the influence of external environmental conditions such as temperature, humidity, and pressure on the electrical characteristics of a material. For example, since conductivity may increase as temperature increases, the environmental compensation unit (224) can compensate for the resistance measurement value based on the value of the temperature sensor. In addition, since changes in humidity or pressure may also affect the electrical characteristics of the material in the electrode sensing member (210) and the storage container (20), the environmental compensation unit (224) can reflect these variables in real time. In addition, the environmental compensation unit (224) can increase the reliability of the measured values ​​by incorporating a compensation algorithm.

[0104] The prediction unit (225) can analyze past data, such as usage patterns, supply cycles, and seasonal changes, to predict future consumption or replenishment times of materials. The prediction unit (225) can apply machine learning or statistical prediction algorithms to provide customized prediction functions for each user or site. The prediction unit (225) can provide the generated prediction information to the display unit (230) or an external system to provide users with appropriate replenishment times, warnings, etc. Furthermore, the prediction unit (225) can support cloud-based data analysis and remote monitoring via wireless and wired network connections.

[0105] In this way, the resistance-based level detection device (200) according to one embodiment of the present invention can dramatically improve the efficiency and safety of storage management in various industrial fields such as energy, chemistry, food, and environment by overcoming the limitations of existing mechanical detection methods.

[0106] FIG. 8 is a configuration diagram of a resistance-based level detection device applied to a liquid storage container according to one embodiment of the present invention.

[0107] Referring to FIG. 8, the liquid level detection device (300) may include an electrode detection member (310), a measuring unit (320), a calculation unit (330), and a prediction unit (340).

[0108] The liquid level detection device (300) can be applied to various liquid storage containers such as fuel storage tanks, chemical solution storage tanks, and water tanks.

[0109] The electrode sensing member (310) is installed vertically inside the liquid storage tank (30), and a pair can be arranged parallel to each other and spaced apart. Each electrode sensing member (310) is divided into several sections such as an upper section, a middle section, and a lower section in the length direction, and the resistance value can be designed to change in steps for each section. For example, the upper section can have a resistance value of 10Ω to 10KΩ, the middle section can have a resistance value of 10KΩ to 1MΩ, and the lower section can have a resistance value of 1MΩ to 100MΩ.

[0110] When the liquid is filled in the storage tank (30), the electrode sensing member (310) may be immersed in the liquid to a level corresponding to the liquid level. At this time, a path for current to flow between the electrode sensing members (310) may be formed due to the electrical conductivity of the liquid. The overall resistance value of the electrode sensing member (310) may vary depending on the height at which it is in contact with the liquid. That is, as the liquid level rises, more resistance sections may be immersed in the liquid, thereby changing the resistance of the entire circuit.

[0111] The measuring unit (320) can apply a certain voltage or current to the electrode sensing member (310), measure the resistance value in real time, and transmit it to the calculation unit (330).

[0112] The calculation unit (330) can convert the measured resistance value into the height (level) of the liquid based on the correlation between the preset resistance value and the height. The calculation unit (330) can also convert the height of the liquid into volume using the cross-sectional area or shape information of the storage tank (30). In addition, the calculation unit (330) can perform more accurate volume calculations by taking into account the density and temperature of the liquid.

[0113] Since conductivity may vary depending on the temperature, concentration, ion concentration, etc. of the liquid, the calculation unit (330) may receive data from auxiliary sensors such as a temperature sensor and a concentration sensor and perform dynamic compensation. In addition, long-term stable measurement may be possible by preventing polarization and corrosion of the electrode using an AC signal.

[0114] The prediction unit (340) learns usage patterns based on liquid level data and can predict future replenishment times or expected depletion points. The prediction unit (340) analyzes past liquid usage data to derive seasonal and time-of-day usage patterns, and based on this, can guide users on optimal replenishment timing.

[0115] FIG. 9 is a configuration diagram of a resistance-based level detection device applied to a solid particle storage container according to one embodiment of the present invention.

[0116] Referring to FIG. 9, the solid particle level detection device (400) may include an electrode detection member (410) and a dispersion member (420).

[0117] The solid particle level detection device (400) can be applied to a solid particle storage facility (40) such as a grain silo, a powder storage facility, a pellet storage facility, etc. The solid particle level detection device (400) can precisely detect the height of solid particles in the storage facility (40), i.e., the storage amount.

[0118] A solid particle level detection device (400) may include a pair of electrode detection members (410) installed vertically inside a storage unit (40). The electrode detection members (410) may be divided into several sections, such as an upper section, a middle section, and a lower section, in the longitudinal direction (height direction), and may be designed such that the resistance value of each section changes stepwise. For example, the upper section may be configured to have a resistance value of 10Ω to 10KΩ, the middle section to have a resistance value of 10KΩ to 1MΩ, and the lower section to have a resistance value of 1MΩ to 100MΩ.

[0119] When solid particles are filled in the reservoir (40), the electrode sensing member (410) may be immersed in the particles to the same height as the accumulated particles. If the solid particles are electrically conductive, a path through which current can flow may be formed between the electrode sensing members (410). At this time, as the particles are accumulated higher, more resistance sections are immersed in the particles, and thus the resistance value of the entire circuit may change. That is, the higher the particle level, the lower the overall resistance, and the lower the particle level, the higher the resistance.

[0120] The control unit connected to the electrode sensing member (410) can measure the change in resistance value between the electrode sensing members (410) in real time. Based on the correlation between the preset resistance value and the height, the control unit can convert the measured resistance value into the height of the solid particle. Using the cross-sectional area or shape information of the storage unit (40), the particle height can be converted into volume to calculate the storage amount.

[0121] If the solid particles do not have sufficient conductivity, conductivity can be secured by mixing in a small amount of conductive additive or by controlling the humidity of the storage (40). For example, a conductive path can be provided by mixing in 0.1 to 1% of conductive particles such as metal powder or carbon black, or by maintaining the relative humidity at 60 to 80% to form a moisture film on the particle surface.

[0122] In addition, if solid particles in the storage (40) are concentrated and accumulated on one side, a detection error may occur. To prevent this, the present invention may additionally include a dispersing member (420). The dispersing member (420) may be implemented as a vibration device, a rotary blade, an air injection device, etc., and may be used to evenly distribute the particles in the storage (40). For example, by applying a low-frequency vibration of 1 to 10 Hz or operating a rotary blade to stir the particles, the particles may evenly accumulate around the electrode sensing member (410), thereby increasing the accuracy of detection.

[0123] The control unit monitors measured resistance values ​​in real time and can apply compensation algorithms based on environmental changes such as temperature, humidity, and particle density. This enables reliable level detection even in diverse solid particle environments.

[0124] FIG. 10 is a drawing showing an example of application of electrically conductive materials in a resistance-based level detection device according to one embodiment of the present invention.

[0125] Referring to FIG. 10, a resistance-based level detection device (200) according to one embodiment of the present invention can be applied to various electrically conductive materials. The present invention can detect levels for various types of materials, such as ice, liquids, and conductive solid particles, using the same principle.

[0126] First, (a) in the case of ice, ice is solid water and has a certain level of electrical conductivity. Since ice produced in ice makers, freezers, etc. contains trace amounts of ionic components, when ice accumulates between electrode sensing members, a path for electric current to flow can be formed. As the height of the ice increases, more sections of the electrode sensing members are submerged in the ice, and thus the resistance value of the entire circuit can be lowered. The device of the present invention can detect such resistance value changes in real time and precisely measure the height of the ice, i.e., the level. In addition, although the electrical characteristics of ice may change somewhat depending on temperature changes, the control unit of the present invention can compensate for the influence thereof through auxiliary means such as a temperature sensor.

[0127] Next, (b) in the case of liquids, the present invention can also be applied to level detection of various conductive liquids such as fuel, chemical solutions, and salt water. Since liquids provide a continuous conductive path compared to solids, the resistance value can change sensitively depending on the height to which the electrode sensing member is immersed in the liquid. For example, in a highly conductive liquid such as salt water, the resistance value can change significantly even with a small change in height. On the other hand, in the case of liquids with low conductivity such as fuel or some chemical solutions, the detection sensitivity can be increased by adjusting the material of the electrode sensing member or the resistance value for each section, or by controlling the frequency of the measurement signal such as an AC signal. In addition, since the conductivity can vary depending on changes in the concentration, temperature, ion concentration, etc. of the liquid, the calculation unit of the present invention can compensate for these factors in real time to enable more accurate level measurement.

[0128] Finally, (c) in the case of conductive solid particles, the present invention can also be applied to level detection of various solid particulate materials such as metal powder, carbon particles, and conductive polymers. When an electrode sensing member is installed in a solid particle storage, a path through which current can flow can be formed between the electrodes depending on the height of the accumulated particles. The resistance value of the entire circuit varies depending on various factors such as particle size, packing density, and contact resistance between particles, and the control unit of the present invention can analyze this change in resistance value to calculate the height of the particles, i.e., the storage amount. If the solid particles do not have sufficient conductivity, conductivity can be secured by mixing a small amount of conductive additive or controlling the humidity of the storage. In addition, a dispersing member such as a vibration device or a rotating blade can be additionally applied to increase the uniformity of particle distribution.

[0129] In this way, the resistance-based level detection device (200) according to one embodiment of the present invention can maintain reliable level detection even under various environmental conditions by applying a correction algorithm according to the characteristics of each material, such as temperature, concentration, and particle size.

[0130] FIG. 11 is an expanded block diagram of an intelligent control system in a resistance-based level detection device according to one embodiment of the present invention.

[0131] Referring to FIG. 11, the extended control unit (500) may include a material determination unit (510), a correction algorithm unit (520), a communication unit (530), and a learning unit (540).

[0132] The resistance-based level detection device (200) can detect the levels of various materials more precisely and intelligently through an advanced control system based on artificial intelligence (AI).

[0133] First, the material identification unit (510) can automatically identify the type of material present in the storage. This identification unit (510) can automatically identify whether the material present in the storage is ice (solid), liquid, or conductive solid particles by measuring the initial resistance value and analyzing its temporal and spatial patterns. For example, the electrical characteristics and type of the material can be identified in real time by comprehensively analyzing the rate of change in the resistance value, the distribution of the resistance value in a specific section, and the correlation with environmental information such as temperature and humidity.

[0134] The correction algorithm unit (520) can apply various correction algorithms suitable for the characteristics of the identified material. Specifically, correction may include correction of resistance values ​​according to temperature changes, correction according to changes in density or concentration of each material, and correction according to external environmental changes such as humidity and pressure. For example, in the case of liquids, since conductivity may change depending on temperature, correction values ​​may be applied in real time based on values ​​measured by a temperature sensor. In the case of solid particles, an algorithm that considers the influence of packing density or inter-particle contact resistance may be applied. In this way, the correction algorithm unit (520) can always provide highly reliable level detection results in response to various environmental changes and material characteristics.

[0135] The communication unit (530) supports various communication protocols, allowing the device to be easily integrated into an IoT (Internet of Things) environment. The communication unit supports both wired (Ethernet, RS-485, etc.) and wireless (Wi-Fi, Bluetooth, LoRa, etc.) communications, enabling real-time data exchange with external systems or cloud servers. This allows users to monitor the storage level status in real-time, even from a remote location, and even enable remote control and configuration changes when necessary. Cloud integration can provide advanced services such as real-time monitoring, predictive analysis, anomaly detection, and maintenance notifications. For example, if the material level in the storage changes rapidly or an abnormal pattern is detected, an immediate notification can be sent to the manager.

[0136] The learning unit (540) can apply an AI-based machine learning algorithm to learn usage patterns and continuously improve prediction accuracy. By analyzing past level change data, usage patterns, seasonal and time-of-day trends, the learning unit (540) can predict future material replenishment or depletion times, and the likelihood of abnormal situations. Furthermore, by generating a customized prediction model based on the user's actual usage patterns, the learning unit can provide a level management solution optimized for each site.

[0137] In this way, the resistance-based level detection device (200) according to one embodiment of the present invention can enable real-time remote management and implementation of a smart factory by monitoring and controlling the storage status from a remote location through a communication unit.

[0138] Although one embodiment of the present invention has been described above, the spirit of the present invention is not limited to the embodiments presented in this specification, and those skilled in the art who understand the spirit of the present invention will be able to easily propose other embodiments by adding, changing, deleting, or adding components within the scope of the same spirit, but this will also be considered to fall within the spirit of the present invention.

Claims

1. As a resistance-based level detection device, A pair of electrode sensing members installed in a storage container, wherein at least one electrode sensing member is a pair of electrode sensing members using a material having a characteristic in which the resistance value varies depending on the length; and A control unit that supplies electricity to the pair of electrode sensing members and converts an electrical characteristic value measured by current conduction by a material stored between the pair of electrode sensing members into a height of the material; Including, The control unit is a resistance-based level detection device that predicts the amount or usage pattern of the stored substance, calculates the replenishment time or alarm of the stored substance, or provides information to the communication unit to enable remote monitoring and control.

2. In paragraph 1, A resistance-based level detection device, wherein the control unit includes a correction algorithm that calculates the height of a material by correcting the difference in electrical characteristics according to the type of stored material.

3. In paragraph 1, The above control unit is a resistance-based level detection device that calculates information on whether the storage container is full, the amount of available material, and the replenishment period based on the height of the material produced, and provides this to the display unit.

4. In paragraph 1, The above control unit is a resistance-based level detection device that learns the usage pattern of the stored material to predict the replenishment time and enables remote monitoring and control through the communication unit.

5. In paragraph 1, The above electrode sensing member is a resistance-based level sensing device in which the upper, middle, and lower parts each have different resistance values.

6. In paragraph 1, If the stored substance is ice or conductive solid particles, The above electrode sensing member is a resistance-based level sensing device that calculates the height of stored solid particles by using the change in resistance value according to the accumulation state of solid particles.

7. In paragraph 1, If the stored substance is a liquid, The above control unit is a resistance-based level detection device that calculates the height and volume of a liquid by correcting in real time changes in electrical characteristics according to the temperature, concentration, and ion concentration of the liquid.

8. In paragraph 1, If the stored material is a solid particle having electrical conductivity, A resistance-based level detection device further comprising a dispersing member in the storage container to ensure that solid particles are evenly distributed within the storage container.

9. In paragraph 1, A resistance-based level sensing device wherein the storage container is at least one of an ice storage tank, a liquid storage tank, a solid particle storage tank, a slurry storage tank, and a gel storage container.

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