Acoustic Array Liquid Level Sensor Wave Redirection
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Solution Overview
Problem
Existing acoustic array liquid level sensors face limitations such as the need for costly edge machining, contamination risks from damping strips, and wave diffraction artifacts, which complicate accurate liquid level detection and are not easily mountable in all liquid holding tanks.
Innovation Solution
The implementation of diversion arrays and collimation grooves to redirect sensing waves, eliminating multiple reflections and diffraction issues, respectively, without the use of damping strips and edge machining, allowing for broader liquid compatibility and flexible mounting options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic damping strips are added to suppress multiple reflections, then measurement precision is improved, but reliability deteriorates due to liquid contamination and chemical attack
Solution Approach 1:
The patent removes the acoustic damping strips from the liquid environment entirely by redirecting sensing waves away from substrate edges using diversion arrays. This extraction eliminates the reliability issue of strips being contaminated or chemically attacked while maintaining the function of suppressing multiple reflections through geometric wave redirection.
Solution Approach 2:
The diversion arrays act as intermediary structures that redirect sensing waves away from substrate edges before they can cause harmful multiple reflections. This mediator approach suppresses spurious signals without requiring direct contact between damping materials and the liquid, thus maintaining both precision and reliability.
2Measurement precision
If sensor substrate edges are machined to reduce multiple reflections, then measurement precision is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces mechanical edge machining with acoustic wave redirection using diversion arrays. Instead of modifying the substrate geometry through costly precision machining, the invention uses acoustic principles to redirect sensing waves, achieving the same suppression of multiple reflections through a lower-cost manufacturing process.
Solution Approach 2:
The invention changes the approach from geometric parameter modification (edge machining) to acoustic parameter control (wave redirection angles and paths). By controlling the acoustic wave propagation parameters through diversion array geometry, the system achieves precision without expensive mechanical processing.
3Measurement precision
If sensor substrate width is increased to accommodate arrays, then measurement precision is improved, but adaptability deteriorates due to inability to mount in small tanks
Solution Approach 1:
The patent addresses the width constraint by folding the sensor substrate into a three-dimensional configuration. This dimensionality change allows the arrays to maintain their required separation distance and geometry for precise measurement while the folded structure reduces the overall footprint to fit through small mounting openings in various tank configurations.
Solution Approach 2:
The folded substrate configuration allows the sensor arrays to be nested within a compact form factor. The arrays are arranged in a folded pattern that maintains their functional separation while fitting within a smaller external envelope, enabling mounting in tanks with limited access openings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the accuracy and versatility of liquid level sensing by reducing spurious components, eliminating the need for costly machining, and enabling mounting through various tank configurations, thereby improving the range and reliability of liquid level detection.
Implementation Method 1
sensing waves are generated at the source array by primary source wave conversion. The source waves themselves are generated by transducer. They then travel at right angles to the source array axis and convert back to secondary source waves at the receive array
Implementation Method 2
At the liquid interface, as the source waves in the source array travel from above to below the liquid, the desired signal amplitude changes from high to low to indicate presence of liquid because sensing waves are absorbed by the liquid
Data Source
AI summary
An ultrasonic sensor detects a liquid level. A substrate (707) has an acoustic array (705). An acoustic diversion array (710) can be between a substrate edge (713) and the acoustic array. A sensing region (701) can lay next to the acoustic array opposite the acoustic diversion array. A collimation groove (706) can be in the substrate along a length of the acoustic array next to the liquid level sensing region. Multiple longitudinal folds (801, 802, 803) can run parallel to and between acoustic source and receive arrays. A feed strip (1201, 1202, 1309, 1311) can be used with a bend (1203, 1204) acoustically coupled to the acoustic array and an ultrasonic transducer at another end of the feed strip. The feed strip runs along the entire acoustic array when top fed and runs along part of the acoustic array when fed through a side of a tank (1401).