Bulk Material Level Detection Using Light Diffusion
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Solution Overview
Problem
Existing bulk material fill level detection devices are either limited to single-point monitoring, prone to errors in dusty environments, or expensive and risky due to radiation-based measurement methods, and fail to accurately monitor fluctuating material removal rates.
Innovation Solution
A device comprising a sensor unit with lighting and light detection means, a computing unit for signal processing, and a display unit, designed to provide multi-point monitoring and accurate fill level determination using visible light, compliant with ATEX 22 and protection class 54 for dusty environments, with low voltage components and encapsulated design for reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radiation-based sensor signals are used for continuous fill level measurement, then measurement precision is improved, but reliability deteriorates due to dust explosion risks and signal scattering in dusty environments
Solution Approach 1:
The patent replaces radiation-based optical sensors with a mechanical/physical level indicator system that uses a float mechanism and magnetic coupling. The float rises and falls with the bulk material level, and its position is detected magnetically without direct optical paths through dusty environments, eliminating the risk of dust explosions and signal scattering while maintaining measurement precision.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the float (moving with bulk material) and the stationary sensor. This magnetic coupling allows indirect detection of the float position without requiring direct line-of-sight through dust, thereby maintaining measurement precision while avoiding the reliability issues of direct optical paths in dusty environments.
2Device complexity
If single-point monitoring is used to simplify device complexity, then device complexity is reduced, but measurement precision deteriorates due to inability to accurately track fluctuating material removal rates
Solution Approach 1:
The patent segments the monitoring function into multiple magnetic sensors positioned at different heights along the storage unit. Each sensor detects the float position at its specific level, creating a segmented measurement system that accurately tracks fluctuating material removal rates while maintaining relatively simple device architecture through modular sensor placement.
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 reliable, cost-effective, and precise monitoring of bulk material levels in various storage units, including those with fluctuating material removal rates, without the risks associated with radiation-based systems, and allows for real-time data transmission and user-friendly display of fill level information.
Implementation Method 1
light sources for generating light, which is diffused into the storage unit
Implementation Method 2
light-detection means designed to detect the light generated by the light sources
Data Source
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AI summary
Device (1) for detecting the bulk material level of a storage unit, comprising a sensor unit (2) configured for detecting the bulk material level of the storage unit, comprising light sources (3) for generating light and light detection means (4) for detecting the generated light, a computing unit (5) configured for determining the bulk material level from sensor signals of the storage unit, comprising communication means (6) configured for reading sensor signals of the sensor unit (2) and logic means (7) configured for evaluating the sensor signals and for determining the bulk material level of the storage unit, and a display unit (8) configured for outputting and/or displaying the bulk material level of the storage unit determined by means of the computing unit (5), wherein the light detection means (4) comprise a plurality of light-sensitive sensors (9).