External Acoustic Sensor for Non-Contact Liquid Fill Level Detection
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Solution Overview
Problem
Current methods for determining the fill level of liquids in intermediate bulk containers (IBCs) are inaccurate, require direct contact with the container, have high power consumption, and necessitate recertification, leading to increased maintenance intervals and costs.
Innovation Solution
A method using a sensor device attached to the outside of the IBC to generate and detect audio signals, combined with a data-driven model and container-specific information, to determine the fill level without direct contact and recertification, optimizing maintenance intervals and reducing idle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sensor device is attached to the outside of the container to determine fill level, then direct contact with the container is avoided and recertification is not required, but measurement precision may be reduced
Solution Approach 1:
The patent uses audio signals as an intermediary medium to transmit fill level information from the container to the sensor device without requiring direct physical contact between the sensor and the liquid or container interior. The audio signals bounce off the liquid surface and carry information about the fill level, enabling external measurement while maintaining precision.
Solution Approach 2:
The patent replaces traditional mechanical contact-based fill level sensors with an acoustic field-based measurement system. Instead of using mechanical probes that physically touch the liquid or container, the system uses sound waves to detect fill level, eliminating the need for direct contact while maintaining measurement accuracy.
2Measurement precision
If traditional contact-based sensor devices are used, then measurement precision is maintained, but power consumption increases and maintenance intervals increase
Solution Approach 1:
The patent implements periodic acoustic stimulation rather than continuous monitoring. The sensor device emits audio signals at specific intervals and measures the reflected signals, which reduces power consumption compared to continuous operation while maintaining measurement precision through periodic updates of the fill level data.
3Measurement precision
If contact-based measurement methods are used, then accurate fill level detection is achieved, but maintenance intervals increase due to direct contact wear
Solution Approach 1:
The patent introduces audio signals as an intermediary that enables fill level detection without direct contact between the sensor device and the container contents. This intermediary approach eliminates wear from direct contact, extending the maintenance interval while preserving measurement accuracy through the acoustic reflection method.
4Productivity
If more IBCs are used for transportation to reduce idle time, then productivity increases, but costs increase
Solution Approach 1:
The patent implements a feedback mechanism where fill level data is continuously monitored and transmitted, enabling real-time decision-making about when containers are full or empty. This feedback allows for optimized scheduling and consolidation of transportation routes, improving productivity by reducing idle time without requiring additional containers through better utilization of existing ones.
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 fill level determination, reduces maintenance intervals, and decreases the number of IBCs needed for transportation, resulting in lower costs and improved product cycles.
Implementation Method 1
acoustically stimulating the container by means of the sensor device to generate at least one audio signal being indicative of the fill level of the liquid in the container
Implementation Method 2
detecting the generated audio signal(s) and optionally processing the detected audio signal(s)
Data Source
AI summary
Disclosed herein are methods and systems for non-invasively determining the fill level in a container. Further disclosed herein are methods and systems for determining the fill level in a container using a sensor device attached to the outside of the container to generate and detect an audio signal and using the detected audio signal in combination with container specific information and a data driven model to determine the fill level in the container.