Micromechanical Capacitor Array for Tank Level Sensing
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Solution Overview
Problem
Conventional fill level sensors are expensive, complex to install, and require extensive calibration for each tank type and shape, limiting their flexibility and economic viability for large-scale monitoring.
Innovation Solution
A fill level sensor with a plurality of micromechanical electrodes arranged in a row, forming discrete capacitors that can be individually measured, allowing for precise capacitance evaluation and flexible installation on various tank shapes without extensive calibration, coupled with a communication module for wireless monitoring and geolocation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensor systems are used for level measurement, then measurement precision can be achieved, but device complexity and production cost increase significantly
Solution Approach 1:
The sensor probe is divided into multiple discrete capacitor units arranged in series, each with its own electrodes. This segmentation allows each capacitor to be independently measured and evaluated, simplifying the overall sensor system while maintaining measurement precision through the cumulative effect of multiple discrete measurements.
Solution Approach 2:
The sensor system is designed with a universal probe structure that can be applied to different tank types and shapes without requiring individual calibration. The standardized capacitor arrangement enables the same sensor design to serve multiple applications, reducing device complexity while maintaining measurement accuracy across various tank configurations.
2Measurement precision
If conventional sensor systems are calibrated for each tank type, then measurement accuracy improves, but installation time and cost increase
Solution Approach 1:
The sensor probe is pre-configured with a standardized arrangement of capacitor units during manufacturing. This preliminary configuration eliminates the need for time-consuming on-site calibration for different tank types, as the sensor's geometric relationships are already optimized for general application. The probe is ready for immediate use across various tank configurations.
Solution Approach 2:
The sensor system employs a universal probe design that can be applied to different tank types and shapes without requiring individual calibration. The standardized capacitor arrangement enables the same sensor design to serve multiple applications, significantly reducing installation time and calibration requirements while maintaining measurement accuracy.
3Measurement precision
If specialized sensors are manufactured for each tank type, then measurement precision improves, but production cost increases
Solution Approach 1:
The sensor system uses a universal probe design with standardized capacitor units that can be manufactured using the same process for different tank types. This universality eliminates the need for specialized manufacturing for each application, significantly reducing production costs while maintaining measurement precision through the consistent capacitor arrangement and measurement methodology.
Solution Approach 2:
By dividing the sensor into discrete, modular capacitor units, the invention enables standardized mass production of identical components that can be assembled in series. This modular segmentation allows for efficient manufacturing using conventional techniques, reducing production costs while maintaining the precision needed for accurate level measurement across different tank configurations.
4Ease of manufacture
If a cylindrical rod sensor is used, then ease of manufacture improves, but adaptability to different tank shapes decreases
Solution Approach 1:
The sensor probe incorporates a flexible cable or rod that can be configured to match the specific geometry of different tank shapes. This dynamic adaptability allows the same standardized capacitor units to be positioned optimally in various tank configurations, maintaining measurement precision while accommodating diverse tank geometries without requiring custom manufacturing.
Solution Approach 2:
The segmented capacitor arrangement along the flexible probe allows each capacitor unit to be positioned independently to match the tank's geometric characteristics. This segmentation combined with the flexible support structure enables the sensor to adapt to different tank shapes while maintaining manufacturing simplicity through the use of standardized, modular components.
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 precise, cost-effective, and low-maintenance monitoring of tank fluid levels and flow, allowing for real-time data collection and tank volume determination without the need for individual tank calibration, while also detecting contamination and leaks.
Implementation Method 1
The underlying physical principle is based on determining the capacitance of a capacitor, whereby the dielectric constant of the space between the capacitor's electrodes varies depending on the medium located between the electrodes, thus allowing a change in capacitance to be measured.
Implementation Method 2
the dielectric constant of the space between the capacitor's electrodes varies depending on the medium located between the electrodes
Data Source
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AI summary
The invention relates to a level sensor (1) for measuring the level of a fluid (2) in a tank (3), comprising a level probe (4) and a measuring circuit (7), wherein the level probe (4) has a plurality of pairs of micromechanical electrodes (5) arranged in series, each forming a micromechanical capacitor (6), wherein the micromechanical electrodes (5) of each micromechanical capacitor (6) are arranged at a fixed distance (d1) from each other, and the volume between the micromechanical electrodes (5) of each micromechanical capacitor (6) is freely accessible to a fluid (2) located in the tank (3) when the level probe (4) is used in the tank (3), and the measuring circuit (7) is designed and connected to the micromechanical capacitors (6) in such a way that the capacitances of the individual micromechanical capacitors (6) are measurable.In this way, a level sensor (1) is provided for measuring the level of a fluid (2) in a tank (3), which can be used flexibly for any tank shapes and tank types without much calibration effort.