Liquid Level Gauge Removable Sensor Module Anti-Tamper Design
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Solution Overview
Problem
Existing liquid level gauges for tanks, such as those for liquefied petroleum gas and propane, are inconvenient for manual and electronic level determination, especially for portable tanks where the gauge is out of view, leading to equipment downtime and increased costs due to the need for specialty magnets and complex manufacturing processes.
Innovation Solution
A liquid level gauge system with a dial assembly and sensor module that includes a go-no-go protrusion and cavity system to prevent unauthorized sensor modules, allowing for secure electronic level determination while maintaining compatibility with existing gauges, and using a bar magnet actuator to rotate a pointer assembly for visual and electronic level indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical gauge head with sending unit is installed in the tank, then liquid level can be determined, but the gauge head is out of operator's view and requires manual reading, causing inconvenience and potential equipment downtime
Solution Approach 1:
The patent replaces the traditional mechanical gauge reading system with an electronic sensor module that uses magnetic fields to detect liquid level. The sensor module converts mechanical float movement into electronic signals that can be displayed on remote devices, eliminating the need for manual gauge reading and allowing operators to monitor levels conveniently from a distance.
Solution Approach 2:
The patent introduces an electronic sensor module as an intermediary between the mechanical float mechanism and the display system. This sensor module acts as a mediator that converts mechanical movements into electronic signals, enabling remote monitoring and eliminating the direct line-of-sight requirement between the operator and the gauge head.
2Reliability
If a removable sensor module is used, then unauthorized modules can be prevented through go-no-go features, but the device complexity increases due to additional locking and alignment mechanisms
Solution Approach 1:
The patent employs asymmetric go-no-go protrusion and cavity features on the sensor module and dial assembly. These asymmetric geometric features ensure that only authorized sensor modules with matching complementary features can be properly installed, providing a simple yet effective anti-tampering mechanism without complex electronic verification systems.
Solution Approach 2:
The patent divides the sensor module into separable components with specific interface features (protrusions and cavities) that must match the dial assembly. This segmentation allows for easy installation and removal of authorized modules while preventing unauthorized ones, balancing security with simplicity.
3Measurement precision
If specialty magnets and complex manufacturing processes are used for existing gauges, then accurate liquid level indication is achieved, but manufacturing costs increase
Solution Approach 1:
The patent replaces expensive specialty magnets with a cost-effective magnetic sensor module that uses standard magnetic field detection technology. The sensor module can be manufactured using conventional processes and materials, significantly reducing manufacturing costs while maintaining accurate liquid level detection capabilities through electronic signal processing.
Solution Approach 2:
The patent substitutes complex mechanical magnetic coupling mechanisms with an electronic sensor module that detects magnetic fields electronically. This replacement eliminates the need for precision-machined magnetic components and complex assembly processes, reducing manufacturing complexity and cost while preserving measurement accuracy.
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 convenient, accurate, and secure electronic determination of liquid levels in tanks, reducing downtime and manufacturing costs by preventing unauthorized sensor module installation and utilizing a cost-effective actuator system for level indication.
Implementation Method 1
a bar magnet actuator to rotate a pointer assembly
Implementation Method 2
at least one sensor located in the housing for determining movement of the actuator from one position to another in response to a change in liquid level within the tank
Data Source
AI summary
An indicator assembly for determining a liquid level condition within a tank includes a dial assembly with a base and a lens or cover connected to the base. A channel is formed in the lens and a go-no-go protrusion projects into the channel. An actuator is located between the base and the cover and is movable in response to a change in liquid level in the tank. The indicator assembly also includes a sensor module for insertion into the channel. The sensor module has a housing with a sensor for determining movement of the actuator in response to a change in liquid level. A go-no-go cavity complementary in shape with the go-no-go protrusion is formed in the housing so that the sensor module can be fully inserted into the housing with the sensor aligned with the actuator for generating signals related to the liquid level condition.