Optical Liquid Volume Monitoring Under Container Motion
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Solution Overview
Problem
Accurate measurement of liquid volume in containers is challenging, especially when the container is in motion, leading to inefficiencies in industrial maintenance and potential failures due to imprecise liquid surface estimation.
Innovation Solution
A system utilizing image analysis from optical sensors to estimate liquid volume in containers, incorporating geometrical analysis and machine learning models to provide real-time, accurate volume monitoring, enabling predictive and preventive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If customary techniques for evaluating the liquid surface are used, then the measurement process is simple, but the measurement precision deteriorates when the container is in motion
Solution Approach 1:
The patent replaces mechanical liquid level measurement techniques with optical sensing and image processing systems. Optical sensors capture images of the liquid surface, and computer vision algorithms analyze these images to determine liquid volume, eliminating the need for mechanical contact with the liquid while improving accuracy during motion.
Solution Approach 2:
The patent introduces an intermediary processing layer between the liquid surface and the measurement system. Image processing algorithms and geometric models act as intermediaries to interpret optical sensor data, converting raw images into accurate liquid volume measurements while compensating for motion effects.
2Productivity
If periodic maintenance is performed at set intervals, then the maintenance schedule is simple to manage, but productivity deteriorates due to wasteful and inefficient maintenance practices
Solution Approach 1:
The patent implements continuous feedback through real-time liquid volume monitoring. The system constantly measures liquid levels and compares them against expected values, providing ongoing information about system health and enabling maintenance decisions based on actual conditions rather than fixed schedules.
Solution Approach 2:
The patent enables preliminary detection of potential failures by continuously monitoring liquid volume trends. The system can identify abnormal patterns before they lead to failures, allowing maintenance to be performed proactively at the optimal time rather than reactively after breakdowns occur.
Data Source
AI summary
A system for monitoring a liquid volume includes processing circuitry. The processing circuitry inputs at least one image of a liquid contained in a container from one or more optical sensors. The volume of the liquid in the container is estimated from the input image(s). The estimated liquid volume is analyzed to determine whether it is consistent with an expected liquid volume. The analysis may be based on a single estimated liquid volume or multiple liquid volumes (for example liquid volumes estimated from images captured at different respective times). An indicator is output based on the results of the analysis.