Offset Sensor Arrays for Tank Calibration Precision
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Solution Overview
Problem
Conventional methods for calibrating large storage tanks are time-consuming and costly, and existing optical sensing systems lack an optimized sensor configuration to accurately measure offsets and deformations, relying heavily on the design of optical sensors for precise calculations.
Innovation Solution
A sensing device with linear arrays of optical sensors offset along a longitudinal axis, providing redundancy and covering gaps, allowing for accurate detection of laser radiation and enabling precise measurement of offsets and deformations, including the use of high-resolution photodiodes and filter elements to minimize stray radiation and enhance sensitivity to the laser wavelength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional fill-and-drain method is used for tank calibration, then tank capacity can be determined, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces the mechanical fill-and-drain method with an optical sensing system that uses laser radiation and photodetectors to measure tank wall deformations and calculate capacity, eliminating the need for physical fluid movement and significantly reducing calibration time
Solution Approach 2:
The patent introduces an optical intermediary (laser beam) that interacts with the tank wall to provide measurement information, allowing capacity determination without direct mechanical interaction or fluid filling
2Productivity
If optical sensing is used for tank calibration, then calibration time is reduced, but measurement accuracy depends heavily on optical sensor design
Solution Approach 1:
The patent divides the optical sensing system into multiple photodetectors arranged in arrays, with each detector capturing light at specific positions. This segmentation allows for more precise determination of laser beam position and tank wall offset through comparative measurements
Solution Approach 2:
The patent changes the optical parameters by using multiple photodetectors with different positions and orientations to detect light intensity variations, enabling more accurate calculation of offset distances through mathematical processing of multiple optical signals
3Device complexity
If a single linear array of optical sensors is used, then device complexity is reduced, but gaps in coverage reduce measurement accuracy
Solution Approach 1:
The patent merges multiple linear arrays of photodetectors into a unified sensing system, where the arrays are positioned to overlap and cover each other's gaps. This combination ensures continuous coverage along the tank wall while maintaining manageable device complexity
Solution Approach 2:
The patent transitions from a single linear array to multiple arrays arranged in different spatial dimensions and orientations, creating a two-dimensional or three-dimensional sensor configuration that provides comprehensive coverage and eliminates blind spots
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 enables highly accurate and efficient measurement of tank surface offsets and deformations, improving the precision of tank calibration by ensuring comprehensive coverage of the laser beam and providing rotational information, while minimizing errors due to misalignment and stray radiation.
Implementation Method 1
an optical sensor 108 coupled to the robotic device... light from the laser reference device 106 is continually detected by the optical sensor 108
Data Source
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AI summary
A sensing device for measuring an offset along a longitudinal axis comprises a housing including a plurality of slots, two or more arrays of optical sensors aligned along the longitudinal axis, at least one of the arrays being offset along the longitudinal axis with respect to the other arrays and a microcontroller coupled to the two or more arrays of optical sensors and configured to determine a positional offset along the longitudinal axis at which light is detected by at least one of arrays of optical sensors. In some embodiments, each of the optical sensors of the arrays are positioned within the housing underneath one of the plurality of slots to reduce an angle of incidence of radiation received.