Integrated Sensor Device for Liquid Level and Optical Detection
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Solution Overview
Problem
Existing sensor systems for monitoring liquid substances in containers, such as those used in exhaust-gas treatment systems, require multiple sensors and complex wiring, leading to increased production costs and complexity.
Innovation Solution
A compact sensor device integrating level-sensing, optical, and temperature-sensing arrangements within a single casing, sharing common control and connection circuitries, with a single connector for signal transmission, and an optical module that can be easily pre-assembled and mounted, reducing the need for multiple sensors and simplifying interfacing with control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate sensors are used for level detection, optical detection, and temperature detection, then measurement precision and reliability are improved, but device complexity and wiring complexity increase
Solution Approach 1:
The patent combines level-sensing, optical detection, and temperature-sensing arrangements into a single integrated sensor device with a common casing. Multiple sensors that would traditionally be separate are merged into one unit, sharing common control circuitry and connection interfaces, thereby reducing wiring complexity while maintaining measurement reliability.
Solution Approach 2:
The sensor device is designed as a multi-functional unit that can perform level detection, optical detection, and temperature detection simultaneously. The device includes a common connector and shared control circuitry that can interface with external control systems to manage multiple sensing functions through a single interface, reducing the need for multiple separate connections.
2Adaptability or versatility
If multiple separate sensors are installed on the container, then comprehensive monitoring capabilities are improved, but production costs and installation complexity increase
Solution Approach 1:
The patent integrates multiple sensing functions into a single manufactured unit. By combining level-sensing, optical, and temperature-sensing arrangements in one device, the patent reduces the number of separate components that need to be manufactured, tested, and installed individually, thereby lowering production costs while maintaining comprehensive monitoring capabilities.
Solution Approach 2:
The sensor device is designed as a universal monitoring unit that can detect multiple parameters (level, optical characteristics, temperature) simultaneously. This multi-functional design allows a single device to replace multiple specialized sensors, simplifying the manufacturing process and reducing overall system cost while providing versatile monitoring capabilities.
3Device complexity
If a compact integrated sensor device is used, then device complexity and production cost are reduced, but measurement precision may be compromised
Solution Approach 1:
The patent combines multiple sensing arrangements in a common casing with carefully designed internal configurations. Each sensing arrangement (level-sensing, optical, temperature-sensing) maintains its functional integrity through proper positioning and shielding within the integrated device, ensuring that measurement precision is preserved despite the compact integration.
Solution Approach 2:
The sensor device incorporates local optimization for each sensing function within the integrated structure. The casing is designed with specific features such as optical paths, sensing zones, and shielding elements positioned to ensure that each measurement function operates with high precision. The local design of each sensing arrangement within the unified device maintains detection accuracy while achieving system simplification.
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
The solution enables a more reliable, cost-effective, and compact sensor system that can replace traditional level sensors, providing additional functionality with minimal software updates, while maintaining precision and accuracy in detecting liquid levels and characteristics.
Implementation Method 1
generating a radiofrequency signal in a resonant circuit and for propagating the resulting electromagnetic radiation in the substance, as well as for detecting changes in the impedance and resonance of the aforesaid circuit
Implementation Method 2
generating a radiofrequency signal in a resonant circuit and for propagating the resulting electromagnetic radiation in the substance
Implementation Method 3
An emitter directs a light beam towards a prism, which constitutes a tip of the sensor and is configured for refracting the radiation into the liquid
Implementation Method 4
the reflected light being detected by a receiver. The reflected light is considered directly proportional to the refractive index of the substance
Implementation Method 5
a temperature-sensing arrangement, with these arrangements that are operatively associated to one and the same casing or assembly body
Data Source
Figure 1
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Figure 3~4
AI summary
A sensor device for a container of a liquid substance comprises a body (10a) with a housing portion (12) having a closing structure (21), the body (10a) having an inner surface and an outer surface. The housing portion (12) is pre- arranged for assembly on the container, in such a way that at least one portion of the outer surface of the body (10a) faces the inside of the container to be in contact with the liquid substance, and the inner surface of the body (10a) is isolated from the inside of the container. Associated to the body (10a) is a first arrangement (15b) for detection of the level of the substance. Associated to the body (10a) of the device (10) is a second arrangement (41) for detection of at least one characteristic of the substance, which comprises at least one emitter (42) and at least one receiver (44a, 44b) of a given optical radiation, such as a radiation in the visible or in the infrared. At least one first portion of the body (10a) of the device (10) is made of a material designed for propagation of the given optical radiation, the at least one emitter (42) and the at least one receiver (44a, 44b) being optically coupled to the inner surface of the body (10a) at said first portion. The aforesaid first portion of the body (10a) of the device (10) is shaped to contribute to propagation of the given optical radiation, in particular by refraction and/or reflection, from the at least one emitter (42) to the at least one receiver (44a, 44b), in such a way that the given optical radiation is at least in part propagated through said first portion of the body (10a) of the device (10) towards the at least one receiver (44a, 44b), in particular at an angle and/or with an intensity that are/is variable as a function of a characteristic of the liquid substance.