Foldable Container Fill Level Sensor Acute Angle Integration
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Solution Overview
Problem
Existing container fill level monitoring systems require opening or direct inspection, leading to contamination risks and inefficiencies in just-in-time production, and existing solutions are limited in accuracy and reliability, especially for non-transparent containers.
Innovation Solution
A foldable container with a fill level sensor integrated into the peripheral wall that emits radiation at an acute angle towards the bottom wall, allowing continuous monitoring without opening the container, using time-of-flight or radar principles for accurate level detection, and is designed for flush integration to prevent contamination and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a signal conductor arrangement is formed in a side wall to monitor fill level, then it is possible to detect whether the level is below a defined level, but it is only possible to monitor a single threshold level and not the exact fill level continuously
Solution Approach 1:
The side wall is segmented into multiple evaluation zones (first, second, third zones) at different heights, each with its own signal conductor arrangement. This allows the system to detect multiple discrete fill level thresholds simultaneously, providing more precise monitoring information without requiring a single complex continuous measurement system.
Solution Approach 2:
Instead of implementing a full continuous measurement system, the patent uses multiple discrete threshold zones that provide sufficient monitoring information for practical purposes. The evaluation device determines fill level by assessing which zones are contacted by the conductive medium, offering a simplified approach that balances precision with system simplicity.
2Reliability
If the container is made of non-transparent material to prevent contamination, then it protects the material inside, but it becomes necessary to open the container to check the current level
Solution Approach 1:
The patent replaces the mechanical action of opening the container for visual inspection with an electrical sensing system. Signal conductor arrangements embedded in the side wall detect fill level through electrical contact with the conductive medium, allowing monitoring through the non-transparent wall without physical access.
Solution Approach 2:
The signal conductor arrangements act as intermediaries between the fill level information and the evaluation device. These conductors are positioned at different heights in the side wall and detect the presence of conductive medium at specific levels, transmitting information about fill status without requiring direct observation or container opening.
3Productivity
If a fill level sensor is provided in a peripheral wall emitting radiation at an acute angle, then continuous monitoring without opening the container is enabled, but the sensor integration complexity increases
Solution Approach 1:
The fill level sensor is merged with the peripheral wall structure itself. The sensor is integrated into the side wall such that the wall serves both as a structural element and as the mounting substrate for the sensing function, eliminating the need for separate sensor housings or additional mounting components.
Solution Approach 2:
The sensor emits radiation at an acute angle relative to the peripheral wall rather than perpendicular to it. This angular orientation allows the radiation to traverse the container interior and reflect off the free surface of the medium, enabling fill level detection through a path that utilizes the wall structure itself as part of the measurement geometry.
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 continuous, accurate monitoring of fill levels without opening the container, reducing contamination risks and inventory costs, improving production efficiency, and allowing for space-saving storage and transport.
Implementation Method 1
using time-of-flight or radar principles for accurate level detection
Implementation Method 2
using time-of-flight or radar principles for accurate level detection
Data Source
Figure 1
Figure 2
AI summary
The present disclosure relates to a container (2) comprising a bottom wall (4), a peripheral wall and a fill level sensor (18) provided on the peripheral wall for measuring a level of a stored material, in particular a liquid filling material, located in the container (2), wherein the fill level sensor (18) emits radiation (20) for determining the level at an acute angle, relative to the peripheral wall, in a direction to the bottom wall (4).