Optical Fill Level Sensor Through Plastic Container Wall
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Solution Overview
Problem
Existing level measurement technologies require an opening in the container for installing non-contact level sensors, limiting their versatility and accuracy for different container types.
Innovation Solution
An optical level measuring device that uses an optical distance sensor to measure the fill level through the container wall, eliminating the need for an opening and allowing for accurate measurements in small plastic containers and industrial environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If non-contact level sensors are installed in an opening of the container, then level measurement can be performed, but the container requires an opening which limits versatility and may affect sealing
Solution Approach 1:
The patent uses the container wall itself as an intermediary medium to transmit optical signals. Instead of requiring direct access to the container interior through an opening, the optical sensor external to the container emits light through the transparent or translucent container wall to detect the product surface, eliminating the need for openings while maintaining measurement capability
Solution Approach 2:
The patent replaces mechanical installation methods (screwing or fastening sensors in openings) with an optical measurement system that operates through the container wall. This substitution eliminates the need for physical openings and mechanical fastening structures, enabling seamless integration with various container types
2Measurement precision
If level sensors are installed inside or in an opening of the container, then measurement can be performed, but the container structure is compromised and sealing is affected
Solution Approach 1:
The container wall serves as an intermediary that allows optical signals to pass through without compromising the container structure. The wall acts as a transparent barrier that transmits light from the external sensor to the product surface, enabling measurement while preserving the container's sealed integrity
Solution Approach 2:
The patent replaces mechanical sensor installation (which requires openings and compromises sealing) with an optical measurement system that operates through the existing container wall. This eliminates the need to open or penetrate the container structure, maintaining sealing integrity while enabling accurate measurement
3Adaptability or versatility
If optical distance sensor is used to measure through container wall, then no opening is needed and versatility is improved, but measurement accuracy may be affected by the container wall material
Solution Approach 1:
The patent compensates for the refractive index differences introduced by the container wall material by adjusting the optical measurement parameters. The evaluation device processes the light signal taking into account the optical properties of the container wall, correcting for any measurement deviations caused by the wall's material characteristics
Solution Approach 2:
The system uses the evaluation device to process and interpret the light signal returned from the product surface, compensating for the effects of the container wall. The evaluation algorithm accounts for the optical path through the wall material, providing accurate fill level measurements despite the intervening container wall
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 reliable and accurate fill level measurements without the need for container openings, effectively addressing the limitations of existing technologies and ensuring precise detection of full and empty states.
Implementation Method 1
emit a light signal through the container wall in the direction of the product surface and to receive the light signal reflected at the product surface
Implementation Method 2
The fill level can be calculated from the running time of the signal from the level sensor to the product surface and back
Implementation Method 3
the level measuring device has a radar sensor which is configured to transmit a radar signal through the container wall in the direction of the product surface and to receive the radar signal reflected at the product surface
Data Source
AI summary
An optical level measuring device configured to measure a fill level of a medium through the container wall of a plastic container, having an optical distance sensor as well as a radar sensor.