Helical Acoustic Liquid Level Sensor Stabilization
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Solution Overview
Problem
Ultrasonic liquid level sensors with helical designs face inaccuracies due to acoustic feedthrough and restricted sensor length caused by helix motion, leading to errors in liquid level readings.
Innovation Solution
The implementation of helix stabilizing rods with reduced acoustic coupling, minimal contact area, and acoustic attenuation in the top plate to prevent spurious waves, along with the use of stabilizing collars and conical-shaped rods to minimize vibrations and reflections, and the incorporation of acoustic absorbing materials in the top plate to reduce interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a helical sensor design is used to increase liquid level resolution, then measurement precision is improved, but acoustic feedthrough causes errors in readings
Solution Approach 1:
The patent introduces an acoustic isolation element as an intermediary component positioned between the helical sensor and the top plate. This mediator blocks the acoustic feedthrough path while allowing the helical sensor to maintain its measurement function, thus resolving the contradiction between improved resolution and maintained accuracy
Solution Approach 2:
The patent extracts and removes the source of acoustic feedthrough by introducing an acoustic isolation element that blocks the unwanted acoustic paths. This separation allows the helical sensor to operate independently without the harmful acoustic coupling to the top plate
2Productivity
If the sensor length is increased to improve measurement range, then productivity is improved, but helix motion restricts the achievable length
Solution Approach 1:
The acoustic isolation element acts as a mediator that also provides mechanical support and stabilization for the helical sensor. This allows the helix to remain stable while extending the sensor length beyond previous limitations
Solution Approach 2:
The patent segments the sensor structure by introducing the acoustic isolation element as a separate component that supports the helical sensor. This segmentation allows independent optimization of the helix stability and the overall sensor length
3Strength
If the top plate provides structural support, then strength is improved, but it creates acoustic feedthrough paths
Solution Approach 1:
The acoustic isolation element serves as an intermediary between the top plate and the helical sensor, allowing the top plate to maintain its structural support function while blocking the acoustic feedthrough paths that would otherwise travel through it
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 solution stabilizes the helix, reduces acoustic feedthrough, and enhances the signal-to-noise ratio, allowing for more accurate liquid level detection and increased sensor length without significant errors, thereby improving the resolution and reliability of the sensor.
Implementation Method 1
an acoustic isolation element can be positioned between a top plate of the sensor and the helix to reduce waves traveling through the top plate to the helix
Implementation Method 2
compressional waves in the liquid cause elastic waves in the helix which then travel to a receiving transducer
Data Source
AI summary
An ultrasonic sensor detects a level of a fluid. A first probe has a first transducer element to transmit an ultrasonic signal through the first probe. A second probe of a helix shape has a second transducer element coiled around the first probe to receive the ultrasonic signal transmitted by the first probe through the fluid. A stabilizing rod and a plurality of stabilizing collets are disposed between the rod and the second probe parallel to both the first probe and the second probe.