Mobile Container Fill Level Sensing With Motion-Adaptive Calculation
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Solution Overview
Problem
Existing filling level sensors for mobile containers require high computing and energy resources, are complex in design, and expensive, especially for autonomous sensors connected to a 4 to 20 mA two-wire line.
Innovation Solution
A level measuring arrangement with a first sensor for distance measurement and a second sensor for orientation/position measurement, along with an evaluation unit that applies different calculation rules based on container movement and fill level changes to determine the fill level or volume, reducing computational demands and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If surface topology scanning is used to increase filling volume accuracy, then measurement precision is improved, but energy consumption and computing resources increase significantly
Solution Approach 1:
The patent divides the bulk material surface into multiple measurement sections, with each section measured by a separate sensor. This segmentation allows the system to achieve comprehensive surface topology scanning without requiring a single complex high-energy sensor, thereby reducing overall energy consumption while maintaining measurement precision.
Solution Approach 2:
The patent employs multiple sensors that can each independently measure distance to different sections of the bulk material surface. These sensors serve multiple functions: individual section measurement, collective surface topology scanning, and redundant measurement capabilities. This multi-functionality approach achieves accurate volume calculation without requiring a single high-power scanning system.
2Measurement precision
If multiple sensors are used to scan bulk material surface topology, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The bulk material surface is divided into multiple discrete measurement sections, each handled by a simple distance sensor. This segmentation transforms a complex single-sensor scanning problem into multiple simple point measurements, reducing individual sensor complexity while achieving comprehensive surface topology data through aggregation.
3Measurement precision
If surface topology scanning is implemented to calculate bulk material volume, then measurement precision is improved, but manufacturing costs increase
Solution Approach 1:
The patent uses multiple standard distance sensors (radar, ultrasonic, or optical) that are commercially available and relatively inexpensive. Each sensor performs a simple distance measurement function, but collectively they enable complex surface topology scanning and volume calculation. This multi-functionality approach achieves high measurement precision using off-the-shelf components rather than custom expensive scanning systems.
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 accurate fill level or volume determination with reduced energy and cost requirements by adapting calculation rules to the container's position and fill level changes, minimizing measurement deviations.
Implementation Method 1
a first sensor which is configured for distance measurement. Examples of such a first sensor are radar sensors, ultrasonic sensors or optical sensors that perform time-of-flight measurements.
Data Source
AI summary
A fill level measurement arrangement for determining a level or volume of a filling material in a mobile container, including a first sensor, for distance measurement, a second sensor, for position measurement, and evaluation circuitry, that determines by analysis of the position measurement or the position measurement whether the mobile container has been moved since a previous measurement of the level, and that applies a first calculation rule in the subsequent calculation of the level or the volume if the mobile container has been moved since a previous measurement, whether the mobile container has been moved since a previous measurement, and in the subsequent calculation of the filling level or the volume from the distance measurement that applies a first calculation rule if the mobile container has been moved since the previous measurement and a second calculation rule if the mobile container has not been moved since the previous measurement.