Microwave Fluid Level Sensor for Pressurized Liquid Gas Containers
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Solution Overview
Problem
Existing liquid level measurement devices for pressurized containers, such as those for LPG or LNG, face challenges including mechanical parts that can jam, difficulty in installation or replacement, exposure to high pressures, and the need for hermetic sealing to protect sensitive components.
Innovation Solution
A container with an opening for mounting a microwave fluid level sensor on the outside, featuring a plastic lid capable of transmitting microwave beams, allowing for non-invasive and cost-effective measurement of the liquid level without exposing sensitive components to high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical float level indicators or magnetostrictive probes are used, then liquid level measurement is achieved, but mechanical parts can be jammed or fail to work accurately on low liquid level
Solution Approach 1:
The patent replaces mechanical measurement systems (float indicators, magnetostrictive probes) with a microwave radar measurement system. The sensor emits microwave signals that travel through the gas phase to the liquid surface and reflect back, enabling contactless measurement that eliminates mechanical wear and jamming issues while maintaining measurement accuracy across all liquid levels.
Solution Approach 2:
The patent introduces microwave radiation as an intermediary medium to transfer measurement information from the liquid surface to the sensor. The microwave beam acts as a mediator that can penetrate the gas phase and interact with the liquid surface without requiring direct mechanical contact, thus resolving the reliability issues of mechanical parts.
2Measurement precision
If radar tank gauge elements are mounted inside the container, then measurement is achieved, but elements are exposed to high pressures and aggressive chemical substances
Solution Approach 1:
The patent extracts the sensitive radar sensor elements from the harsh internal environment of the pressurized container and relocates them to the external environment. The sensor is mounted on the outer surface of the container wall, allowing it to measure liquid level through the container wall without being exposed to high pressure or corrosive chemicals inside the container.
Solution Approach 2:
The patent utilizes the container wall itself as a transmission medium for microwave signals. The thin wall structure allows microwave radiation to penetrate through it, enabling the external sensor to measure internal liquid level without direct exposure to the harsh internal environment, while the wall acts as a protective barrier.
3Reliability
If hermetic sealing is applied to protect sensor elements, then protection from high pressure and chemicals is achieved, but radiation characteristics of antennas may change and installation becomes complex
Solution Approach 1:
The patent eliminates the need for hermetic sealing by extracting the sensor from the harsh environment entirely. The sensor is mounted externally on the container surface, using the container wall as a natural barrier, thus avoiding complex sealing requirements while maintaining protection from high pressure and corrosive chemicals.
Solution Approach 2:
The patent changes the operational parameters of the measurement system by moving from internal mounting (requiring hermetic sealing) to external mounting. This parameter change in sensor location eliminates the need for complex sealing arrangements while maintaining measurement capability through the container wall.
4Ease of operation
If through holes are made in the tank for sensor installation, then sensor mounting is achieved, but tank integrity is compromised and installation is difficult
Solution Approach 1:
The patent extracts the sensor installation location from the tank wall interior to the exterior surface. This allows mounting on the outer surface without creating through holes that would compromise tank integrity, while still enabling measurement through the wall material.
Solution Approach 2:
The patent inverts the traditional mounting approach by placing the sensor on the outside of the container rather than inside. This inversion allows the sensor to measure internal liquid level through the container wall without requiring holes or openings in the tank structure, thus preserving tank integrity while enabling installation.
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 provides a simple, cost-effective, and reliable method for measuring the fill level of pressurized liquid gases, eliminating the drawbacks of existing technologies while ensuring the safety and integrity of the measurement system.
Implementation Method 1
a microwave fluid level sensor (4) mounted on the outside of the container (1) over the opening (2) and configured to emit a microwave beam towards the inside of the container (1) and to receive a beam reflected by the surface of the liquid
Implementation Method 2
Known radar tank gauge operates on the principle of a microwave transit time measuring method for determining the fluid level in a container
Implementation Method 3
said lid is made of a plastic material capable of transmitting at least a part of said microwave beams
Data Source
AI summary
A container for pressurized liquid gas, such as LPG or LNG, having an opening leading from outside to inside of the container and having a microwave fluid level sensor mounted on the outside of the container over the opening and configured to emit a microwave beam towards the inside of the container and to receive a microwave beam reflected from the surface of the liquid inside the container. Between the microwave fluid level sensor and the inside of the container there is a lid closing the opening, wherein the lid is made of plastic material capable of transmitting at least a part of the microwave beams.