Liquid Level Sensor Calibration Using Relay Power Control
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Solution Overview
Problem
Existing liquid level monitoring systems in containers or reservoirs face challenges in accurately measuring liquid levels due to varying tank sizes and shapes, and require manual calibration, which is cumbersome and unreliable, especially for large or hazardous tanks, and fail to provide accurate readings when the ignition is turned OFF.
Innovation Solution
A liquid level monitoring system that includes a liquid sensor, a fixed voltage feed, a sampling unit, a calibration unit, and a relay unit to power the sensor when the machine is OFF, allowing for continuous monitoring and calibration, using mathematical representations to account for varying tank geometries and ignition conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration is performed by incrementally filling the container, then liquid level measurement can be obtained, but the process becomes very cumbersome and time consuming
Solution Approach 1:
The system performs calibration during normal operation by continuously monitoring the relationship between sensor voltage and liquid level changes as liquid is consumed or added. This preliminary action during operational phases eliminates the need for separate, time-consuming manual calibration procedures.
Solution Approach 2:
The calibration system uses the vehicle's own fuel consumption and refilling operations to automatically calibrate the sensor. The system self-calibrates by monitoring voltage changes during natural liquid level variations, eliminating the need for external manual calibration processes.
2Ease of manufacture
If a pre-calibrated sensor is installed, then the installation process is simplified, but the system becomes unsuitable for after market applications with varying tank geometries
Solution Approach 1:
The system adapts to different tank geometries by dynamically adjusting the calibration parameters through mathematical models. The calibration unit modifies sensor voltage interpretations based on the specific tank shape and size, allowing a single sensor design to work across multiple tank configurations.
Solution Approach 2:
The calibration approach transitions from static pre-calibration to dynamic calibration that continuously adapts to the specific tank geometry. The system learns and adjusts calibration parameters based on actual operational data from the specific vehicle's tank, enabling versatility across different geometries.
3Reliability
If conventional sensors are used, then the system works during ignition ON, but the sensor fails to provide readings when ignition is turned OFF
Solution Approach 1:
The relay unit enables periodic sampling of sensor voltage even when ignition is OFF, allowing calibration data collection during both ignition ON and OFF states. This periodic action ensures continuous monitoring capability without requiring constant power to the sensor.
Solution Approach 2:
The relay unit acts as an intermediary that provides power to the sensor during ignition OFF periods when the main system is inactive. This mediator component enables the sensor to function during both ignition states without directly connecting the sensor to the always-on power supply.
4Measurement precision
If tanks are calibrated individually for their specific geometry, then measurement accuracy is improved, but the complexity of the calibration process increases
Solution Approach 1:
The calibration unit serves multiple functions: it monitors sensor voltage during operation, performs mathematical transformations of the data, stores calibration information, and applies corrections during both ignition ON and OFF states. This multi-functionality reduces the need for separate dedicated components for each calibration task.
Data Source
AI summary
A system for monitoring level of a liquid in a reservoir of a machine is provided. The system includes a liquid sensor (112) that measures said level of said liquid in said reservoir, a fixed voltage feed (110) that generates a regulated voltage, a sampling unit (114) that samples one or more parameters of the machine and a calibration unit (124) that calibrates the system for monitoring the level of said liquid in a reservoir of a machine in one or more modes to obtain a mathematical relation between the parameter and the level of the liquid. The calibration unit executes a calibration process during a first mode and obtains a calibrated data that corresponds to the parameter during a second mode.