Optical Fluid Level Gauging for Non-Collapsible Dispensers
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Solution Overview
Problem
Existing fluid level gauges, particularly optical fluid level gauges, are inadequate for accurately monitoring fluid levels in non-collapsible reservoirs in real-time, failing to provide reliable estimates of the remaining fluid quantity and changes in fluid levels.
Innovation Solution
A fluid level gauging mechanism with multiple vertically spaced optical sensors external to the reservoir, emitting and sensing electromagnetic radiation to determine the fluid level by comparing radiation intensity at different sensor heights, activated during dispenser use or replenishment events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single optical sensor is used in a fluid level gauge, then the device complexity is reduced, but the measurement precision and reliability of fluid level monitoring deteriorates
Solution Approach 1:
The fluid level gauge is segmented into multiple independent optical sensors positioned at different vertical heights. Each sensor independently monitors fluid level at its specific height, and the controller integrates signals from multiple sensors to determine overall fluid level status, thereby improving measurement precision while maintaining manageable device complexity
Solution Approach 2:
The invention transitions from a single-point measurement approach to a multi-dimensional measurement approach by distributing sensors vertically at different heights. This spatial distribution across multiple dimensions enables more comprehensive fluid level monitoring and improves measurement accuracy without proportionally increasing complexity
2Reliability
If multiple vertically spaced optical sensors are used externally to the reservoir, then the measurement precision and reliability of fluid level monitoring is improved, but the device complexity increases
Solution Approach 1:
Multiple optical sensors serve the universal function of detecting electromagnetic radiation transmission through the reservoir wall. Each sensor performs the same basic function but at different vertical positions, allowing the system to reliably determine fluid level by comparing signals across sensors without requiring complex specialized components for each sensor
Solution Approach 2:
The controller merges and integrates signals from multiple independent optical sensors to produce a unified fluid level determination. By combining the information from multiple sensors in a centralized control unit, the system achieves high reliability in fluid level monitoring while managing device complexity through integrated signal processing
3Speed
If optical sensors are positioned closely adjacent to the reservoir wall, then the response time for detecting fluid level changes is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The system dynamically adapts to variations in sensor positioning by using relative comparisons between multiple sensors rather than absolute position references. The controller can adjust and calibrate the system after installation, allowing sensors to be positioned closely to the reservoir wall for fast response while compensating for manufacturing tolerances through software-based positioning correction
4Measurement precision
If the reservoir wall is made transparent to electromagnetic radiation, then the optical sensing capability is improved, but the material selection and manufacturing options are restricted
Solution Approach 1:
The system changes the parameter of electromagnetic radiation wavelength to achieve transmission through different reservoir materials. By selecting appropriate wavelength ranges that penetrate specific materials (such as infrared for certain plastics), the system maintains measurement precision across various reservoir material types without restricting material selection
Solution Approach 2:
The electromagnetic radiation acts as an intermediary that passes through the reservoir wall to enable sensing. By using radiation types that naturally penetrate common reservoir materials, the system achieves good optical sensing capability while maintaining compatibility with diverse reservoir materials, and the controller can compensate for varying transmission characteristics
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
Provides accurate and real-time monitoring of fluid levels in non-collapsible reservoirs, enabling effective fluid management and timely replenishment by distinguishing between sensor positions above or below the fluid surface based on radiation intensity.
Implementation Method 1
an emitter of electromagnetic radiation within a range of wavelengths, and a plurality of sensors of electromagnetic radiation within the range of wavelengths... the wall of the reservoir permitting electromagnetic radiation within the range of wavelengths to pass through the wall
Implementation Method 2
each sensor located outside of the reservoir exterior of the wall but closely adjacent to the exterior surface of the wall to receive electromagnetic radiation emitted by the emitter into the cavity of the reservoir that passes outwardly through the wall proximate the sensor
Data Source
AI summary
A hand cleaning liquid dispenser including a fluid level gauging mechanism with a plurality, preferably three or more, vertically spaced optical sensors located closely adjacent an external of a side wall of the reservoir to each receive electromagnetic radiation transmitted through the side wall from within the reservoir with the electromagnetic radiation sensed originating from an emitter directing the electromagnetic radiation preferably through the reservoir downwardly.