Float Sensor Inclination Compensation for Opaque Container Level Monitoring
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Solution Overview
Problem
Existing solutions for monitoring the level of liquids in opaque containers, such as metal containers, are cumbersome, costly, and difficult to install, requiring space and specialized configurations, and often interfere with storage or require level ground conditions.
Innovation Solution
A float component with a sensor and controller that estimates the inclination of the float within the liquid, allowing for wireless communication of liquid level information to external devices, eliminating the need for external apparatuses and simplifying the monitoring process by physically contacting the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a sight glass is installed on the container, then the liquid level can be visually assessed, but the installation becomes complex and may not be practical for all container types
Solution Approach 1:
The patent replaces the mechanical sight glass system with a magnetic field-based sensing system. The float contains a magnet that generates a magnetic field, which is detected by a magnetic sensor (such as a Hall effect sensor or reed switch) mounted on the container exterior. This substitution eliminates the need for mechanical installation modifications to the container while enabling liquid level detection.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the float inside the container and the sensor outside the container. The magnet in the float creates magnetic field lines that extend through the container wall to activate the magnetic sensor, allowing communication of liquid level information without direct physical contact or complex installation.
2Ease of operation
If an external scale is used to monitor liquid level, then the liquid level can be determined, but additional space is required and the container cannot be stored on level ground
Solution Approach 1:
The patent extracts the liquid level sensing function from the external environment and relocates it inside the container. The float and magnetic sensor system are self-contained, with the sensor mounted on the container exterior but the sensing mechanism operating internally through the magnetic field. This eliminates the need for external space and level ground requirements.
Solution Approach 2:
The patent replaces the mechanical scale system with a magnetic field-based sensing system. Instead of measuring weight externally, the system uses magnetic field detection to determine liquid level, eliminating the need for external support structures and level ground.
3Measurement precision
If existing level sensors are used, then the liquid level can be measured, but they are costly, take up space, and are time consuming to configure
Solution Approach 1:
The patent segments the liquid level measurement function into discrete magnetic sensors positioned at specific height intervals on the container exterior. Each sensor corresponds to a specific liquid level threshold. This segmentation allows for simple configuration by placing sensors at required levels without complex setup procedures.
Solution Approach 2:
The patent replaces complex electronic level sensors with simple magnetic sensors (such as reed switches or Hall effect sensors) that respond to the magnetic field from the float. These sensors are inexpensive, require minimal configuration, and provide reliable liquid level detection through magnetic field interaction.
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 easy, space-efficient, and cost-effective monitoring of liquid levels within containers, allowing users to assess remaining liquid volume without direct contact, suitable for various applications from retailer to manufacturer, including metal containers like beer kegs.
Implementation Method 1
The sensor senses a parameter usable to determine an inclination of the float component
Implementation Method 2
A float component with a sensor and controller that estimates the inclination of the float within the liquid
Data Source
AI summary
In one embodiment, an apparatus may meter a level of a liquid. The apparatus includes a float component, wherein the float component includes a sensor and a controller. The sensor senses a parameter usable to determine an inclination of the float component. The controller is operable to receive the sensed parameter, and communicate information based on the sensed parameter to an external controller. When operating to determine a level of a liquid within a container, the apparatus physically contacts the container. Further, at least one of the controller or the external controller is operative to estimate the inclination of the float component based on the sensed parameter, and determine the level of the liquid within the container based on the estimated inclination.