Acoustic Bin Content Mapping Using Non-Collinear Receiver Arrays
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Solution Overview
Problem
Current methods for measuring the content of bulk solid inventory in bins, such as silos, face challenges due to unfavorable conditions like dust, extreme temperatures, and complex geometries, leading to inaccurate and unreliable measurements, especially in the presence of 'coning' phenomena and obstacles.
Innovation Solution
A system utilizing an array of non-collinear acoustic receivers and a processing apparatus to transmit and receive pulses of acoustic energy, correlating waveforms to compute directions of arrival and distances, allowing for three-dimensional mapping of the upper surface and estimation of content volume and mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If ultrasonic level sensors are used to measure content height, then the measurement range can be extended, but the measurement accuracy deteriorates in the presence of dust
Solution Approach 1:
The patent transitions from single-point height measurement to three-dimensional surface mapping by using an array of receivers positioned at multiple locations. This dimensional expansion allows the system to capture the entire upper surface geometry, including coning phenomena, rather than just a single height value, thereby maintaining accuracy despite dust interference.
Solution Approach 2:
The patent replaces mechanical contact-based measurement methods with acoustic wave-based measurement. By using acoustic energy transmission and echo reception, the system achieves non-contact measurement that is not affected by dust accumulation on mechanical components, resolving the accuracy-dust contradiction.
2Measurement precision
If radar level sensors are used to measure content height, then the measurement accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent substitutes electromagnetic radar waves with acoustic waves for level measurement. This substitution achieves comparable measurement accuracy while using simpler, more cost-effective acoustic transducers and signal processing equipment, thereby reducing device complexity.
Solution Approach 2:
The patent divides the measurement function into multiple independent acoustic receivers positioned at different locations. Each receiver independently measures local surface characteristics, and the results are integrated to form a complete three-dimensional map, achieving high accuracy without requiring a single complex radar system.
3Device complexity
If capacitance sensors are used to measure content level, then the device complexity is reduced, but the measurement precision deteriorates due to sensitivity to humidity and material type
Solution Approach 1:
The patent replaces electrical capacitance-based measurement with acoustic wave-based measurement. Acoustic wave propagation and reflection characteristics are independent of humidity and material dielectric properties, thereby achieving measurement accuracy without the sensitivity issues that plague capacitance sensors while maintaining relatively simple device architecture.
4Ease of operation
If mechanical level sensors are used to measure content height, then the ease of operation is improved, but the reliability deteriorates due to clogging and getting stuck
Solution Approach 1:
The patent replaces mechanical contact-based level sensors with non-contact acoustic wave measurement. Acoustic waves pass through dust and air without being blocked or stuck by obstacles, eliminating the reliability problems of mechanical sensors while maintaining ease of operation through automated acoustic measurement.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium to transfer measurement information from the bulk material surface to the receivers. This intermediary approach allows indirect measurement without physical contact, avoiding clogging and mechanical entanglement issues.
5Ease of manufacture
If conventional level sensors are used to measure content height, then the ease of manufacture is improved, but the measurement precision deteriorates in the presence of coning phenomena
Solution Approach 1:
The patent expands from one-dimensional height measurement to three-dimensional surface mapping by deploying multiple receivers at different positions. This dimensional expansion enables the system to capture coning geometry and calculate accurate volume and mass, achieving measurement precision that conventional single-point sensors cannot provide.
Solution Approach 2:
The patent segments the measurement task into multiple independent acoustic measurements taken at different receiver positions. By combining these segmented measurements into a three-dimensional surface model, the system achieves accurate volume and mass calculation that accounts for coning phenomena, while each individual receiver remains relatively simple to manufacture.
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 approach provides accurate and reliable measurements of the content height, volume, and mass, overcoming the limitations of existing technologies by accounting for bin shape and internal conditions, including 'coning' and obstacles, and is applicable to various bin geometries.
Implementation Method 1
at least one transmitter for transmitting a pulse of acoustic energy towards an upper surface of the content; an array of at least three non-collinear receivers for receiving an echo of the pulse
Implementation Method 2
High frequency sound waves from a transmitter are reflected by the top surface of the content to a receiver. The height of the content is inferred from the round-trip travel time.
Data Source
AI summary
A system for measuring the height of bin content includes a transmitter for transmitting an acoustic pulse towards the upper surface of the content, a non-collinear receiver array for receiving an echo of the pulse and producing signals in response to the echo, and a processing apparatus for computing one or more directions of arrival of the signals from the upper surface to the array along with corresponding measured distances. Preferably, the receivers are transducers that also serve as transmitters. Two or more such measured distances constitute a map of the upper surface for estimating the quantity of the bin content. Preferably, the system includes a pulse shaper and repeater for optimizing the pulse shape relative to the signals.