Fuzzy Logic Echo Analysis for Accurate Bin Volume Measurement
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Solution Overview
Problem
Current methods for measuring the content of bulk solid inventory in bins, such as silos, are inadequate due to issues like dust interference, extreme temperatures, non-isotropic materials, and complex geometries, leading to inaccurate and unreliable measurements, especially in the presence of 'coning' phenomena and explosive atmospheres.
Innovation Solution
A system utilizing a fuzzy logic module and volume calculator to estimate the volume of bin contents by analyzing received echoes, calculating confidence levels, and distinguishing between true and false echoes, while maintaining a database of reference echoes and updating attributes based on signal-to-noise ratios and other parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional level sensors (electromechanical, ultrasonic, radar, capacitance) are used to measure bulk solid inventory in bins, then measurement capability is provided, but measurement accuracy deteriorates due to dust interference, coning phenomena, complex geometries, and obstacles
Solution Approach 1:
The patent transitions from traditional single-point level measurement to three-dimensional mapping of the bulk material surface. By using multiple receivers arranged in an array and processing echo signals from multiple angles, the system creates a volumetric representation of the material surface, enabling accurate volume calculation even in the presence of dust, coning, and complex geometries that plague traditional single-point sensors.
Solution Approach 2:
The patent divides the measurement task into multiple independent echo reception channels, with each receiver capturing reflections from specific spatial zones. The system segments the bulk material surface into multiple detectable regions and processes each segment's echo data independently before integrating them into a comprehensive three-dimensional model, thereby maintaining accuracy despite local dust interference or obstacles.
2Reliability
If mechanical devices like yo-yo sensors are used, then level measurement is achieved, but reliability deteriorates due to clogging by dust and getting stuck on obstacles
Solution Approach 1:
The patent replaces mechanical measurement devices (yo-yo sensors, weight gauges) with a non-contact acoustic measurement system. Echo sounders transmit acoustic pulses through the air medium and receive reflections from the bulk material surface without any physical contact, eliminating all mechanical failure modes including dust clogging, entanglement with obstacles, and wear from repeated contact with the material.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium to transfer measurement information from the bulk material surface to the receivers. Instead of direct mechanical contact, the acoustic pulses serve as carriers that bounce off the material surface and convey elevation and volume information back to the measurement system, enabling reliable operation in dusty environments.
3Measurement precision
If capacitance sensors are used, then level measurement is provided, but measurement accuracy deteriorates due to sensitivity to humidity and material type variations
Solution Approach 1:
The patent measures multiple acoustic parameters (time of flight, echo amplitude, frequency content) from the bulk material surface and uses these varying parameters to infer material properties and surface geometry. By analyzing changes in acoustic wave characteristics rather than relying on a single capacitance value, the system adapts to different material types and humidity conditions without sacrificing measurement accuracy.
Solution Approach 2:
The patent processes echo signals to extract information about material surface characteristics and uses this feedback to adjust measurement interpretation. By analyzing the reflected acoustic wave properties and comparing them against expected patterns, the system compensates for variations in material type and humidity, maintaining consistent measurement accuracy across different operating conditions.
4Measurement precision
If prior art sensors are used, then level measurement is achieved, but accuracy deteriorates in the presence of coning phenomena and complex bin geometries
Solution Approach 1:
The patent explicitly addresses coning and complex geometries by transitioning from single-point level detection to three-dimensional surface mapping. The multiple receivers capture echo data from different angular perspectives, enabling the system to reconstruct the true three-dimensional shape of the bulk material surface including cones, mounds, and irregularities, and calculate accurate volumes regardless of surface geometry complexity.
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
This approach provides stable and accurate volume measurements that are immune to dust and noise fluctuations, effectively addressing the limitations of existing technologies by mapping the upper surface of the bin contents in three dimensions and handling complex geometries and obstacles.
Implementation Method 1
a transmitter that may transmit pulses of acoustic energy into a bin
Implementation Method 2
a receiver that may receive echoes of the pulses of acoustic energy reflected from an upper surface of the content
Data Source
AI summary
A method, non-transitory computer readable medium and a system that includes a fuzzy logic module arranged to apply a fuzzy logic algorithm for calculating, in response to received echoes that are received by a receiver, confidence levels of origins of received echoes; wherein the received echoes are reflected or scattered from the origins; and a volume calculator that is arranged to calculate a volume of the content in response to (a) estimated locations of the origins, and (b) the confidence levels of the origins.