Fill Level Sensor Disturbance Correction
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Solution Overview
Problem
Conventional fill level measuring systems, such as those using floating sensors or acoustic sensors, fail to provide accurate measurements when the surface of the reservoir content is disturbed by agitation, vibrations, or movements.
Innovation Solution
A fill level measuring system that employs a sensor element capable of transmitting and receiving signals to perform a time-of-flight measurement, with a processing unit that detects surface disturbances and corrects the fill height determination accordingly, using techniques such as moving averages and threshold-based error classification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional floating sensors or acoustic sensors are used to measure fill level, then the measurement system is simple and cost-effective, but the measurement accuracy deteriorates when the reservoir surface is disturbed by agitation, vibrations, or movements
Solution Approach 1:
The patent replaces mechanical floating sensors with an optical/time-of-flight measurement system. The sensor element transmits signals (e.g., optical or electromagnetic waves) toward the reservoir surface and receives reflected signals to calculate fill level based on time-of-flight, eliminating mechanical contact with the fluid and thus immunity to surface disturbances from agitation or vibrations
Solution Approach 2:
The patent introduces a signal transmission medium (optical or electromagnetic waves) as an intermediary between the sensor and the reservoir surface. This intermediary carries measurement information without direct mechanical interaction with the fluid, allowing accurate measurement even when the surface is disturbed by external factors like agitation or vibrations
2Measurement precision
If time-of-flight measurement is used to measure fill level, then measurement accuracy is improved, but the system complexity increases due to signal transmission and processing requirements
Solution Approach 1:
The sensor element is designed to perform multiple functions: transmitting signals toward the reservoir surface, receiving reflected signals, and potentially detecting surface disturbances. This multi-functionality reduces the need for separate components and simplifies the overall system architecture while maintaining high measurement accuracy through time-of-flight measurement
3Productivity
If the sensor element transmits signals continuously to maintain real-time measurement, then measurement responsiveness is improved, but energy consumption increases
Solution Approach 1:
The sensor element transmits signals periodically rather than continuously, maintaining real-time measurement capability while reducing energy consumption. The processing unit evaluates measurement values at appropriate intervals, balancing the need for timely fill level information with energy efficiency in the sensor operation
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 determination of the fill height in reservoirs with irregular surface conditions, improving measurement accuracy by accounting for disturbances caused by agitation or movement.
Implementation Method 1
the time interval between transmission and reception of the signal is subsequently used by a processing unit of the fill level measuring system to conduct a time-of-flight measurement on the basis of this time difference
Implementation Method 2
receive a reflection signal reflected by the surface in response to the measurement signal
Data Source
AI summary
A fill level measuring system (1) for measuring the fill level in a reservoir. The system (1) includes a sensor element (8) arranged relative to a surface (2) of a substance in the reservoir. The sensor element (8) transmits a measuring signal in the direction of the surface (2) and receives a reflection signal reflected from the surface (2) in response to the measuring signal. A processing unit (14), based on the time difference between the transmitting of the measuring signal and the receiving of the reflection signal, carries out a travel time measurement and processes measurement values of the travel time measurement, in order to determine a fill level of the reservoir. The processing unit (14) detects disturbances on the surface (2) and takes the disturbances into account when determining the fill level.