Electromechanical Level Meter Functional Diagnosis Without Interruption
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Solution Overview
Problem
Existing electromechanical level measuring devices require interruption of measurement operations for functional diagnosis, which is time-consuming and lacks real-time monitoring, and the mechanical components are prone to wear, affecting accuracy.
Innovation Solution
A method for functional diagnosis that allows continuous monitoring during measurement operations by varying the equilibrium volume of the displacer element, changing the length of the measuring wire, and determining the resulting weight force, without influencing the fill level measurement, through an evaluation algorithm that adjusts in small steps to compensate for changes and check the integrity of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional diagnosis is performed using existing methods, then the measurement operation can be interrupted to check system status, but the measurement operation must be interrupted which reduces productivity and loses real-time monitoring
Solution Approach 1:
The patent implements continuous functional diagnosis during measurement operations by continuously monitoring the relationship between measuring wire length and resulting weight force. The evaluation algorithm constantly checks whether changes in measuring wire length correspond to expected changes in weight force, enabling real-time detection of mechanical problems without interrupting the measurement process. This maintains both productivity and reliability.
Solution Approach 2:
The system continuously feeds back the relationship between measuring wire length and resulting weight force to the evaluation algorithm, which compares actual measurements against expected values. When deviations indicate mechanical problems (such as wire friction, sticking, or component failures), the system generates diagnostic signals while maintaining continuous measurement operations, providing real-time monitoring without productivity loss.
2Ease of operation
If mechanical components are used in the level measuring device, then the device can perform displacement measurement, but mechanical components are prone to wear which affects measurement precision
Solution Approach 1:
The patent replaces pure mechanical measurement with a hybrid system that combines mechanical displacement measurement with electrical sensing. The resulting weight force is determined electrically by measuring the current required to hold the displacer element in equilibrium, eliminating the need for mechanical force sensors that would wear. This substitution maintains ease of operation while improving long-term measurement precision.
Solution Approach 2:
The system uses the measurement process itself to monitor the health of mechanical components. By continuously analyzing the relationship between measuring wire length and resulting weight force during normal operation, the system detects wear and mechanical degradation without requiring separate maintenance operations, enabling predictive maintenance while maintaining measurement precision.
3Reliability
If the equilibrium volume of the displacer element is varied for functional diagnosis, then the integrity of components can be checked, but the fill level measurement could be influenced by the volume change
Solution Approach 1:
The patent dynamically adjusts the equilibrium volume of the displacer element during functional diagnosis while simultaneously adjusting the resulting weight force to maintain measurement accuracy. The evaluation algorithm compensates for volume changes by calculating the corresponding change in weight force, ensuring that fill level measurements remain accurate even during diagnostic operations that vary displacer volume.
Solution Approach 2:
The system changes the equilibrium volume parameter of the displacer element for diagnostic purposes while using the evaluation algorithm to compensate for these changes in the fill level calculation. By tracking the relationship between volume changes and weight force changes, the system can perform component integrity checks without compromising fill level measurement precision, as the evaluation algorithm adjusts for the known volume variations.
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 automatic functional testing without interrupting measurements, improves accuracy by reducing wear on mechanical components, and ensures continuous operation with enhanced reliability and precision.
Implementation Method 1
the weight of the displacer element minus one of at least one equilibrium volume-dependent buoyancy force of the displacer element is determined to be equal to a resulting weight force of the displacer element
Data Source
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AI summary
The invention relates to a method for the functional diagnosis of an electromechanical fill state measuring device in which a displacement element on a measuring wire is lowered into a filling material in a container such that in an equilibrium state, the weight of the displacement element equals the resulting weight of the displacement element minus a displacement element buoyancy, which depends on at least one equilibrium volume. The resulting weight is specified, and the specified resulting weight is kept constant by correspondingly changing the length of the measuring wire in the equilibrium state. The fill state of the filling material is ascertained using the length of the lowered measuring wire. In order to diagnose a function, the specified value of the equilibrium volume of the displacement element is changed, and the resulting change of the length of the measuring wire is ascertained on the basis of the constant equilibrium state of the resulting weight.