Mobile Container Fill Measurement Using Motion-Adaptive Volume Rules
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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 4 to 20 mA two-wire lines, making them inefficient for accurate volume determination.
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, reduces energy consumption and costs by optimizing volume calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If scanning of the bulk material surface is performed to calculate the topology of the surface, then the accuracy of the filling volume calculation is increased, but the computing resources and energy consumption increase significantly
Solution Approach 1:
The patent extracts only the essential information needed for volume calculation by using discrete point measurements from sensors instead of comprehensive surface scanning. The evaluation unit processes only the necessary distance measurements and container orientation data to determine filling volume, eliminating the need for exhaustive topology scanning while maintaining adequate accuracy for practical applications.
Solution Approach 2:
Instead of performing complete surface scanning, the system uses partial measurements at specific points (distance measurements from sensors positioned at locations such as 12 o'clock, 3 o'clock, 6 o'clock, and 9 o'clock positions) to infer the overall filling volume. This partial measurement approach significantly reduces computing and energy requirements while providing sufficient accuracy for process automation applications.
2Measurement precision
If sensors are used for accurate filling level determination, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs sensors that serve multiple functions: distance measurement sensors (such as radar or ultrasonic sensors) simultaneously provide both level information and, when combined with container orientation data, enable volume calculation. The evaluation unit integrates distance measurements from multiple sensor positions with container orientation measurements to determine both filling level and volume using a single sensor system, reducing overall device complexity.
Solution Approach 2:
The system merges distance measurements from multiple sensor positions (e.g., 12 o'clock, 3 o'clock, 6 o'clock, 9 o'clock positions) with container orientation measurements into a unified evaluation process. The evaluation unit combines these data streams to calculate filling volume, eliminating the need for separate specialized sensors for each measurement type and simplifying the overall device architecture.
3Measurement precision
If multiple sensors and complex calculation rules are implemented, then measurement accuracy is improved, but energy consumption and device cost increase
Solution Approach 1:
The patent implements dynamic adaptability by detecting container orientation changes and automatically adjusting the volume calculation method accordingly. The evaluation unit determines whether the container is in transport position or storage position based on orientation measurements, and selects appropriate calculation rules from a set of predefined rules. This dynamic adaptation maintains measurement accuracy across different container states without requiring complex real-time recalculation, thereby reducing energy consumption.
Solution Approach 2:
The system pre-defines multiple calculation rules for different container states (transport position, storage position, various filling levels) and stores them in advance. When a measurement is taken, the evaluation unit simply selects the appropriate pre-defined rule based on the current container orientation, avoiding the need for complex real-time calculations and reducing both energy consumption and processing time while maintaining 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
The solution provides accurate volume determination with reduced energy and cost requirements by adapting calculation rules to container movements and fill level changes, enhancing measurement precision and efficiency.
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.
Implementation Method 2
a second sensor which is configured to measure an orientation and/or position
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.