Optical Fuel Level Probe Using Emitter Receiver Pairs
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Solution Overview
Problem
Existing fuel level detection methods, such as ultrasonic and capacitive sensors, face challenges like requiring a settled fluid surface, scale factor drift over time or with different fuel mixes, and calibration needs, which can be unreliable in moving vehicles or with sloshing liquids.
Innovation Solution
A digital, transmissive, optical fuel level probe using a circuit board with horizontally mounted emitter/receiver pairs and a processor to determine liquid presence based on data from these pairs, eliminating the need for calibration and operating effectively in sloshing or foamy conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic fuel sensors are used, then liquid level detection is achieved, but the sensor requires a settled fluid surface and a settling tube for reliable operation
Solution Approach 1:
The patent replaces ultrasonic acoustic sensing with optical sensing using emitter/receiver pairs. This substitution eliminates the need for acoustic settling and eliminates the mechanical settling tube structure, as optical detection works reliably regardless of fluid surface settlement or vehicle motion.
Solution Approach 2:
The patent changes the detection parameter from acoustic (ultrasonic) to optical. This parameter change allows detection to occur without requiring fluid surface settlement, as optical detection is not affected by the same acoustic interference issues that plague ultrasonic sensors in moving vehicles.
2Reliability
If capacitive fuel sensors are used, then liquid level detection is achieved, but scale factor drift occurs as they age or with different fuel mixes
Solution Approach 1:
The patent replaces capacitive sensing with optical sensing. This substitution eliminates the scale factor drift problem because optical detection measures light transmission properties that are consistent across different fuel types and do not degrade with sensor aging, unlike capacitive sensors whose electrical properties drift over time.
Solution Approach 2:
The patent changes the detection parameter from electrical (capacitive) to optical. This parameter change provides stable, consistent measurements across different fuel compositions and sensor lifetimes, as optical properties of the fuel do not change with sensor aging and the optical detection mechanism itself remains stable.
3Reliability
If ultrasonic or capacitive fuel sensors are used, then liquid level detection is achieved, but calibration with a scale factor is required
Solution Approach 1:
The patent replaces ultrasonic or capacitive sensing with optical sensing. This substitution eliminates the need for calibration with scale factors, as the optical detection system provides direct, absolute measurements of light transmission that can be converted to level measurements without requiring empirical calibration for different fuel types or conditions.
Solution Approach 2:
The optical detection system is self-calibrating in the sense that it does not require external calibration procedures. The system inherently provides consistent measurements based on optical physics principles that do not vary with fuel composition or sensor aging, eliminating the need for manufacturer or field calibration activities.
4Measurement precision
If multiple emitter/receiver pairs are used, then measurement precision is improved through averaging, but device complexity increases
Solution Approach 1:
The patent divides the detection function into multiple independent emitter/receiver pairs arranged vertically along the circuit board. Each pair independently measures light transmission at its specific height, and the processor integrates these discrete measurements to determine overall liquid level and volume, with multiple measurements providing statistical averaging that improves precision.
Solution Approach 2:
The patent transitions from a single-point detection approach to a distributed multi-point detection array arranged in the vertical dimension. This dimensional expansion allows simultaneous measurement at multiple heights, providing both improved measurement precision through spatial distribution and the ability to calculate liquid volume by integrating across the vertical dimension.
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, calibration-free liquid level measurements in various conditions, including sloshing liquids and different fuel mixes, with increased precision through averaging algorithms and adaptable installation flexibility.
Implementation Method 1
A digital, transmissive, optical fuel level probe using a circuit board with horizontally mounted emitter/receiver pairs and a processor to determine liquid presence based on data from these pairs
Data Source
AI summary
The present disclosure relates to an apparatus and method for liquid level detection. The method may include providing a circuit board including a plurality of horizontally mounted emitter/receiver pairs arranged vertically along the circuit board within a liquid containment area. The method may further include determining, using one or more processors associated with the circuit board, if liquid is present between each of the plurality of emitter/receiver pairs based upon, at least in part, data received from one or more of the plurality of emitter/receiver pairs.