Cable-Based Sensor for Silo Material Level and Temperature Detection
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Solution Overview
Problem
Conventional sensors for detecting material level and temperature in silos are unable to effectively handle solid materials, as their detecting cables are easily damaged by impacts.
Innovation Solution
A cable-based sensor system comprising an electronic box, a cable with steel wires and temperature sensing units, and a stopper that securely positions the cable bud between the stopper and the base, preventing damage from solid materials, while also including a signal processing module for calculating material level and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensors are used to detect material level, then liquid material level can be detected, but the detecting cables are easily damaged by impacts of solid material
Solution Approach 1:
The patent applies beforehand cushioning by providing a protective sheath surrounding the detecting cable. This sheath acts as a protective barrier that absorbs and dissipates impact forces from solid materials before they can damage the cable, thereby preventing damage in advance while maintaining cable functionality for detecting both liquid and solid material levels
Solution Approach 2:
The patent employs composite materials by constructing the sensor cable with multiple layers including a protective sheath and internal cable structure. The sheath is made from material with high impact resistance while the internal components maintain sensing capabilities, creating a composite structure that combines protection with detection functionality
2Adaptability or versatility
If conventional sensors are used to detect material level, then liquid material level can be detected, but the sensor cannot detect solid material
Solution Approach 1:
The patent implements universality by designing the detecting cable with a protective sheath that enables the same cable structure to function reliably with both liquid and solid materials. The sheath protects against solid material impact while allowing the cable to maintain its detecting capability across different material types, making the sensor universally applicable
Solution Approach 2:
The patent applies parameter changes by modifying the physical parameters of the cable system through the protective sheath, which changes the impact resistance parameter while maintaining the electrical and sensing parameters. This allows the sensor to operate with different material densities and impact forces without compromising detection accuracy
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
The sensor system can reliably detect both liquid and solid material levels and temperatures, maintaining its integrity even when impacted by solid materials, ensuring accurate measurements and preventing damage.
Implementation Method 1
The steel wires are mounted around the sensing channel and embedded in the insulation layer. Terminals of the steel wires extend out of the insulation layer and spread to form a cable bud.
Implementation Method 2
The temperature sensing units are mounted in and along the sensing channel.
Data Source
AI summary
A cable-base sensor can detect a material level and temperatures of a material stored in a silo. The cable-base sensor comprises an electronic box, a cable, a stopper, and a signal processing module. The electronic box comprises a base and a space for containing the signal processing module, and a hole is formed through a bottom of the electronic box. The base is mounted in the bottom, and a tapered hole is formed through the base. A first end of the cable extents into the tapered hole and the hole, and spreads to form a cable bud. The stopper is a tapered block and pressed into the tapered hole for enforcing the cable bud to be sandwiched between the stopper and the base. The cable bud strengthens a connection between the electronic box and the cable for preventing damages from solid materials.