Bottom-Mounted Ultrasonic Sensor for Fluid Level and Concentration
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Solution Overview
Problem
Conventional ultrasonic sensors for measuring fluid level and concentration, typically positioned at the top of a tank, face limitations when using a single transducer, as they provide insufficient information for certain calculations and cannot determine fluid conditions in all scenarios.
Innovation Solution
An ultrasonic sensor system positioned at the bottom of a tank, utilizing a single transducer and a controller with a target, generates and receives ultrasonic signals to determine fluid level and concentration, compensating for the limitations of a single transducer by processing echoes and using temperature data to calculate sound speed and fluid properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single transducer is used for ultrasonic measurement, then device complexity is reduced, but measurement precision and information completeness deteriorate
Solution Approach 1:
The patent segments the measurement process into three distinct operational modes based on fluid level relative to the target: Mode 1 (fluid level above target) measures both target distance and fluid surface distance; Mode 2 (fluid level at target) measures target distance only; Mode 3 (fluid level below target) measures fluid surface distance only. This segmentation allows a single transducer to gather sufficient information for accurate measurements by adapting the measurement strategy to different conditions.
Solution Approach 2:
The system dynamically switches between three operational modes based on the detected fluid level relative to the target position. The controller adjusts the measurement approach and calculation methodology according to the current mode, enabling accurate fluid level and concentration determination throughout the entire measurement range using a single transducer.
2Device complexity
If a single transducer is used, then device complexity is reduced, but the ability to determine fluid conditions in all scenarios deteriorates
Solution Approach 1:
The single transducer is designed to perform multiple functions: measuring distance to the target, measuring distance to the fluid surface, determining fluid level, and calculating fluid concentration. By implementing three operational modes, the system ensures that the single transducer can adaptively determine fluid conditions across all possible scenarios, from empty tank to full tank conditions.
Solution Approach 2:
The system uses feedback from the detected echo patterns and time-of-flight measurements to determine which operational mode is active. Based on this feedback, the controller selects the appropriate calculation methodology to accurately determine fluid level and concentration, ensuring versatile fluid condition assessment using a single transducer.
3Adaptability or versatility
If the sensor is positioned at the bottom of the tank, then adaptability is improved, but device complexity increases due to processing requirements
Solution Approach 1:
The controller implements segmented processing by dividing the measurement range into three distinct zones (Mode 1: fluid level above target, Mode 2: fluid level at target, Mode 3: fluid level below target). Each zone has a specific measurement and calculation approach, which simplifies the overall processing complexity compared to attempting a single unified calculation method for all conditions.
Solution Approach 2:
The system changes operational parameters (measurement mode, calculation formulas, reference points) based on the detected fluid level conditions. This parameter adaptation allows the bottom-positioned sensor to achieve comprehensive measurement coverage while managing controller processing complexity through conditional logic rather than complex continuous calculations.
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
Enables accurate measurement of fluid level and concentration, even with a single transducer, by processing echoes and temperature data, providing reliable data for fluid management systems, such as diesel exhaust fluid systems in vehicles.
Implementation Method 1
The transducer is configured to generate an ultrasonic signal, to receive a reflection of the ultrasonic signal from at least one of the target and a surface of a fluid
Implementation Method 2
receive a reflection of the ultrasonic signal from at least one of the target and a surface of a fluid
Implementation Method 3
processing echoes and temperature data, providing reliable data for fluid management systems
Implementation Method 4
the time it takes for the signal to travel from the transducer at the top of the tank to the surface of the liquid, reflect off the surface of the liquid, and return to the transducer is measured
Data Source
AI summary
A three-mode ultrasonic sensor for determining temperature, level, and/or concentration of a fluid. In one embodiment, the sensor includes a target positioned at a level; a controller, and a transducer electrically connected to the controller. The controller is configured to generate an ultrasonic signal, to receive a reflection of the ultrasonic signal from at least one of the target and a surface of a fluid, and generate a signal based on the reflection. The controller is further configured to receive the signal, and determine whether a level of the surface of the fluid is one of the following group: above the level of the target, below the level of the target, and substantially the same as the level of the target.