Hall Sensor Tank Gauge for Precise Liquid Gas Volume Measurement
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Solution Overview
Problem
Existing systems for measuring gas volume in liquid form in a tank rely on visual analog gauges, leading to human errors and potential service interruptions due to inaccurate readings.
Innovation Solution
A system using a rod with a magnet inside a tank, coupled to a longitudinal chamber and Hall effect sensors, generates precise digital measurements of gas volume, with a processor calculating and transmitting alerts for timely refilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual analog gauges are used to measure gas volume, then the measurement can be displayed visually, but human errors occur in reading and recording the measurements
Solution Approach 1:
The patent replaces the mechanical visual analog gauge with an automated sensor-based system. Hall effect sensors detect the position of a magnet attached to a floating rod, converting mechanical position into electrical signals that are processed by a microcontroller to display digital volume readings, eliminating human reading errors
Solution Approach 2:
The system automatically monitors gas volume without requiring manual inspection. The sensors continuously detect magnet position, the microcontroller calculates volume based on pre-stored calibration data, and the system self-updates the displayed reading, eliminating the need for human intervention in measurement taking
2Device complexity
If visual analog gauges are used, then the system is simple in structure, but infrequent reading and recording may lead to gas running out unexpectedly
Solution Approach 1:
The patent implements continuous automated monitoring where Hall effect sensors continuously detect magnet position as the gas level changes. The microcontroller continuously processes sensor data and updates the displayed volume reading in real-time, providing continuous visibility of gas levels without interruption
Solution Approach 2:
The system provides continuous feedback by automatically detecting gas level changes through magnet position detection and immediately updating the displayed volume reading. This real-time feedback loop ensures that users are always informed of the current gas level without requiring manual checking
3Measurement precision
If automated sensor-based measurement is implemented, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the measurement system into distinct functional modules: the floating rod with magnet for detection, the Hall effect sensors for signal acquisition, the microcontroller for processing and calculation, and the display interface. This segmentation allows each component to perform its specific function independently, making the overall complex system easier to design, assemble, and maintain
Solution Approach 2:
The patent introduces a magnet as an intermediary element that couples the mechanical gas level measurement to the electrical sensor system. The magnet attached to the floating rod converts mechanical position into magnetic field variations that the Hall effect sensors detect, serving as a reliable intermediary that simplifies the interface between mechanical and electrical systems
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
Provides accurate digital measurements, reducing human error and ensuring timely refilling to prevent service disruptions.
Implementation Method 1
Each of the first and second sensors is configured to generate a voltage signal corresponding to a strength of magnetic field associated with the magnet
Data Source
AI summary
A system comprises a rod placed inside a tank and configured to move a pre-configured distance as the level of a gas stored in the tank changes. A chamber is positioned in relation to a top region of the tank. A magnet is coupled to an upper portion of the rod and disposed inside the chamber such that the magnet moves with the rod. A circuit board is positioned adjacent to the chamber and includes two sensors positioned along the length of the chamber, wherein each sensor generates a voltage signal corresponding to a strength of magnetic field associated with the magnet. A memory stores voltage values corresponding to the voltage signal and a processor coupled to the memory calculates a volume of the gas in liquid form in the tank based on a voltage value generated by at least one of the sensors.