Optical Sensor for Tank Gauge Remote Monitoring
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Solution Overview
Problem
Conventional tank gauges require manual reading and lack remote access, leading to inconvenience and potential liquid evaporation due to improper installation of electronic gauges or magnet-based systems, which also have limited remote monitoring capabilities.
Innovation Solution
An optical sensor that fits over a conventional tank gauge, using photon beams to monitor the level through a translucent vial, with photoemitters and photodetectors, and a microcontroller for data processing and remote transmission, allowing for remote access and notification of critical levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an electronic gauge using sound waves is installed to enable remote monitoring, then remote access to tank levels is achieved, but the system complexity increases and requires proper installation to prevent liquid evaporation
Solution Approach 1:
The optical sensor assembly is nested over the existing conventional tank gauge, with the sensor housing enclosing the photoemitter, photodetector, and indicator elements while utilizing the gauge's existing measurement vial and indicator mechanism. This nesting approach enables remote monitoring functionality without requiring removal or modification of the original gauge assembly.
Solution Approach 2:
The optical sensor assembly serves multiple functions: it provides remote visual indication of tank levels through LEDs, maintains the traditional direct-reading capability through the measurement vial, and requires no modification to the existing gauge. This multi-functionality resolves the contradiction by adding remote monitoring capability while preserving the original simple installation.
2Ease of operation
If a magnet-based remote monitoring system is installed, then remote level detection is enabled, but the installation process becomes complex requiring removal and reattachment of the measurement vial
Solution Approach 1:
The optical sensor assembly is nested over the existing conventional tank gauge, with the sensor housing enclosing the photoemitter, photodetector, and indicator elements while utilizing the gauge's existing measurement vial and indicator mechanism. This nesting approach enables remote monitoring functionality without requiring removal or modification of the original gauge assembly.
3Ease of operation
If the measurement vial is removed and reattached for electronic gauge installation, then remote monitoring is achieved, but liquid evaporation may occur due to improper sealing
Solution Approach 1:
The optical sensor assembly is nested over the existing conventional tank gauge, with the sensor housing enclosing the photoemitter, photodetector, and indicator elements while utilizing the gauge's existing measurement vial and indicator mechanism. This nesting approach enables remote monitoring functionality without requiring removal or modification of the original gauge assembly.
Solution Approach 2:
The optical sensor assembly is divided into separate functional components: the sensor housing containing electronic elements, the optical path through the measurement vial, and the indicator mechanism. This segmentation allows the sensor to be installed as an add-on module without disrupting the sealed integrity of the measurement vial or requiring its removal from the tank gauge.
4Loss of information
If cable-based transmission is used for remote monitoring, then level data can be transmitted, but the monitoring distance is limited by cable length
Solution Approach 1:
The patent replaces cable-based mechanical data transmission with optical transmission through free space. The photodetector converts optical signals from the measurement vial into electrical signals that can be transmitted wirelessly or over longer distances without the physical constraints of cable length, thereby extending the monitoring distance beyond what cable-based systems allow.
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
Enables remote monitoring of tank levels without disturbing the existing gauge, preventing liquid evaporation and providing immediate visual feedback and automated notifications, enhancing convenience and reliability.
Implementation Method 1
determines the level of a gauge indicator by monitoring photon beams that travel horizontally through a glass (or another translucent material, such as plastic) vial. More specifically, level detection is achieved by checking the state of a photon beam that travels from a photoemitter through a measurement vial to a corresponding photodetector
Implementation Method 2
level detection is achieved by checking the state of a photon beam that travels from a photoemitter through a measurement vial to a corresponding photodetector, such as but not limited to a phototransistor, photodiode, etc.
Data Source
AI summary
An optical sensor for a conventional tank gauge designed to allow a user to remotely check the liquid level of a tank without the need for a visual inspection. Using an emitter circuit board with a plurality of photoemitters and a detector circuit board with a plurality of photodetectors, the optical sensor can fit over a conventional tank gauge without disturbing the gauge. The circuit boards can be attached to an optical sensor frame, which can be adjusted on the conventional tank gauge by a height adjustment screw and a series of set screws. Alternatively, one or more sliders can be used to maintain proper alignment. Analog data generated from the photodetectors can be digitized using a microcontroller and can be made available for viewing on a stationary or mobile device via an integrated network connection.