Acoustic Tank-Bottom Sensor Coupling for Portable Propane Level Sensing
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Solution Overview
Problem
Existing methods for determining the liquid level in propane tanks, such as temperature difference, pressure sensing, weight measurement, visual gauges, and ultrasonic devices, are inaccurate, costly, or require complex setups, making them unsuitable for portable propane tanks.
Innovation Solution
A sensor arrangement comprising a housing with a transducer and couplant, secured to a tray, uses acoustic pulses to measure liquid height in propane tanks, employing a low-power wireless link to transmit data to a display module, and includes a biasing device to ensure accurate coupling with the tank bottom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic pulse devices are used to detect propane level, then measurement capability is provided, but device complexity and cost increase
Solution Approach 1:
The patent extracts the ultrasonic transducer from the complex housing and mounting structures of conventional devices, placing it directly against the tank bottom through a simple couplant interface. This eliminates the need for complex mounting mechanisms while maintaining measurement capability.
Solution Approach 2:
The patent introduces a couplant as an intermediary substance between the transducer and the tank bottom to ensure efficient acoustic coupling. This simple intermediary replaces complex mechanical coupling mechanisms, reducing device complexity while maintaining measurement precision.
2Measurement precision
If ultrasonic devices require coupling to tank wall, then accurate signals are transmitted, but ease of operation decreases due to manual positioning requirements
Solution Approach 1:
The patent incorporates a biasing device that preliminarily positions the transducer against the tank bottom before operation begins. This preliminary action eliminates the need for manual positioning during operation, maintaining signal accuracy while improving ease of operation.
Solution Approach 2:
The biasing device enables the system to self-position the transducer against the tank bottom without requiring user intervention. The device automatically ensures proper coupling through the biasing mechanism, making the system self-sufficient in maintaining optimal measurement conditions.
3Measurement precision
If repeated measurements are taken to locate fluid line, then measurement accuracy improves, but loss of time increases
Solution Approach 1:
The biasing device performs the preliminary action of positioning the transducer against the tank bottom before any measurements are taken. This ensures that the first measurement is already at the correct location, eliminating the need for repeated measurements and reducing time loss.
4Measurement precision
If float-based visual gauges are used, then measurement accuracy improves, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical float-based visual gauge system with an acoustic measurement system. The ultrasonic transducer uses acoustic waves instead of mechanical floats to measure liquid level, eliminating complex mechanical components while maintaining or improving measurement precision.
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
Provides accurate and cost-effective liquid level measurement in portable propane tanks, compatible with tank exchange services, and extends battery life through low-power wireless technology.
Implementation Method 1
The couplant can extend between the transducer and an external environment for transmitting an acoustic pulse from the transducer to a tank bottom for measuring height of a liquid overlaying the transducer
Data Source
AI summary
A sensor arrangement for measuring liquid height in a tank can include a base, a housing, a transducer, and a biasing device. The housing can contain the transducer and a controller. The controller can transmit an acoustic pulse from the transducer for measuring liquid height within the tank. The biasing device can bias the housing towards sensing engagement with a surface of the tank.