Non-Contact Level Switch Using Acoustic Wall Pulses
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Solution Overview
Problem
Existing level sensors for containers face challenges such as requiring contact with the fluid, limited application to certain types of materials, and inability to detect point levels or changes in fluid levels accurately.
Innovation Solution
A non-contact level switch system using a force pulse generator and force sensor to detect fluid levels by analyzing damped signal peaks, determining presence, direction, and preventing over/under-filling through signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact-based level sensors are used, then fluid level can be detected, but the sensor requires contact with the fluid which limits application in harsh environments and certain material types
Solution Approach 1:
The patent replaces mechanical contact-based level sensing with acoustic wave propagation through the container wall. The force pulse generator creates acoustic waves that travel through the container wall and interact with the material inside, allowing non-contact detection that works across various material types (fluids, solids, powders) without sensor contamination or exposure to harsh environmental conditions.
2Measurement precision
If optical level sensors are used, then fluid level detection is achieved, but the sensors maintain contact with the fluid being measured
Solution Approach 1:
The patent introduces the container wall as an intermediary medium that transmits acoustic energy between the force pulse generator and the material being measured. This intermediary allows level detection without direct exposure of the sensor to the fluid, eliminating harmful factors such as corrosion, contamination, and mechanical wear while maintaining measurement precision through analysis of the acoustic wave's interaction with the material.
3Quantity of substance
If existing level sensors are used, then continuous fluid levels are monitored, but point level detection and direction of material movement cannot be determined
Solution Approach 1:
The patent employs feedback analysis of the acoustic wave's return signal characteristics. By analyzing the amplitude, timing, and pattern of the reflected or transmitted acoustic waves, the system determines not only the presence of material at specific levels but also the direction of material movement (filling or emptying), providing comprehensive information about both quantity and state changes.
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
Accurately detects fluid levels and direction without contact, operating in harsh environments, and preventing over/under-filling of containers with fluids, solids, and powders.
Implementation Method 1
a force pulse generator and force sensor to detect fluid levels by analyzing damped signal peaks
Implementation Method 2
processing a damped signal detected by a force sensor in response to the force pulse
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
A device for determining the level and/or direction of various media is provided. A level switch may detect, respond to, and/or control levels and/or overfilling of various media, such as fluids, solids, powders, granules, and/or other materials comprised within a container. A level switch may include a housing, a force sensor comprising a substantially spherical component protruding through an opening of the housing (wherein the force sensor is mechanically coupled to the housing), a force pulse generator configured to impinge a force pulse of a chosen force and pulse width onto a surface of a container (wherein the force pulse generator is mechanically coupled to the housing), and/or a printed circuit board assembly (PCBA) (wherein the PCBA is mechanically coupled to the housing).