Optical Filling Level Detection for Bulk Storage
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Solution Overview
Problem
Existing methods for determining the filling level of storage units, particularly for bulk goods ('C' components), are not sufficiently precise and struggle with variations in material, shape, and size, and fail to accurately measure the last 10% of the storage capacity, which is crucial for efficient warehouse management.
Innovation Solution
A method involving illuminating the storage unit with a pattern of illumination features, capturing reflection images, and using optical sensors to generate and evaluate sensor signals to determine the filling level, independent of material, shape, or size, through the analysis of reflection features and their vectors to create an elevation map.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight measurement methods are used to determine filling level, then the measurement can be performed regardless of material properties, but the precision is insufficient especially for the last 10% of storage capacity
Solution Approach 1:
The patent replaces mechanical weight-based measurement systems with an optical measurement system. The device uses illuminators to project light patterns and optical sensors to detect reflection characteristics, thereby determining filling level without mechanical contact. This substitution enables precise measurement of the last 10% of storage capacity while maintaining reliability across different material types (paper, stainless steel, etc.) that have varying densities and weight characteristics.
Solution Approach 2:
The patent changes the measurement parameter from weight to optical reflection characteristics. By illuminating the storage unit with light patterns and analyzing the reflected light intensity and patterns detected by optical sensors, the system determines filling level based on optical parameters rather than gravitational force. This parameter change allows precise detection of small volume changes in the last 10% of capacity regardless of the material's weight properties.
2Measurement precision
If simple detection devices are used, then the cost is reduced, but the measurement precision and reliability are insufficient
Solution Approach 1:
The patent segments the optical measurement system into distinct functional modules: illuminators for light projection, optical sensors for light detection, and an evaluation device for data processing. Each module performs a specific function, allowing the system to achieve high measurement precision through coordinated operation of relatively simple, low-cost components rather than requiring a single complex detection device.
Solution Approach 2:
The patent creates a universal measurement system that can determine filling level for various materials (paper, stainless steel, bulk goods) using the same optical configuration. The illuminators and optical sensors serve multiple functions: projecting light patterns, detecting reflection intensity, and providing data for filling level calculation. This multi-functionality reduces overall device complexity while maintaining high measurement precision across different application scenarios.
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
This approach provides a reliable, cost-effective, and precise method to determine the filling level, ensuring accurate measurement of the storage unit's content, even in cases of varying article types, and effectively addresses the challenge of measuring the last 10% of the storage capacity.
Implementation Method 1
illuminating the storage unit with at least one illumination pattern comprising a plurality of illumination features and determining at least one reflection image of the storage unit
Data Source
AI summary
Described herein is a method for determining a filling level in at least one storage unit. The method includesilluminating the storage unit with at least one illumination pattern;selecting at least one first reflection feature and at least one second reflection feature;for the first reflection feature, generating at least two first sensor signals, and for the second reflection feature, generating at least two second sensor signals;evaluating the two first sensor signals and the two second sensor signals;determining at least one position of the first reflection feature and at least one position of the second reflection feature and determining at least one first vector of the first reflection feature and at least one second vector of the second reflection feature; anddetermining from the first vector and the second vector at least one elevation map and determining therefrom the filling level in the storage unit.