Optical Triangulation Sensor for Non-Contact Material Level Detection

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Solution Overview

Problem

Conventional methods for detecting the material level in containers, such as propane tanks, suffer from limited accuracy and reliability due to the fragility of moving parts in float-type gauges and the unpredictability of computer-based predictions, while also being expensive to manufacture.

Innovation Solution

An optical non-contact sensor system with a sensor element having an optical emitter and receiver positioned to form a triangular vertex with the material surface, using triangulation to measure the level and volume of the material within the container, which is more accurate and economical, and can be retrofitted into existing containers without breaching the seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If float-type gauge is used to detect material level, then the sensor can provide direct measurement, but the moving parts cause friction and wear leading to limited accuracy and eventual degradation

Engineering Contradiction:

Improvematerial level measurement accuracyVSAvoidsensor durability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces the mechanical float-type gauge system with an optical triangulation system. Instead of using moving mechanical parts (float and linkage) to detect liquid level, the invention uses an optical emitter and receiver positioned at known coordinates to form a triangle with the liquid surface, eliminating mechanical wear and friction while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts the measurement function from the mechanical float system and implements it through optical triangulation geometry. By removing the float and linkage mechanism entirely and using only optical components positioned at fixed points, the system eliminates the sources of friction and wear while preserving the level detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If float-type gauge with moving parts is used, then direct measurement is possible, but fragile portions are susceptible to damage

Engineering Contradiction:

Improvedirect measurement capabilityVSAvoidsensor fragility

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent replaces the fragile mechanical linkage and float components with a robust optical system. The emitter and receiver are positioned at fixed coordinates on the container, eliminating delicate moving parts that connect the float to the measurement mechanism, thereby significantly improving structural strength and damage resistance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If computer-based prediction is used to estimate liquid level, then no direct sensing is required, but reliability in predicting amount of liquid is limited

Engineering Contradiction:

Improvesystem simplicityVSAvoidliquid volume prediction accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent substitutes computer-based predictive algorithms with direct optical measurement. Instead of using software to estimate liquid level based on usage patterns and historical data, the system employs geometric triangulation with optical components to directly measure the liquid surface position, providing accurate real-time data without relying on predictions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If prior art detection systems are implemented, then material level can be detected, but manufacturing cost is high

Engineering Contradiction:

Improvedetection system functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces complex mechanical sensing mechanisms with a simpler optical triangulation system. By using basic optical components (emitter and receiver) positioned at known coordinates rather than sophisticated mechanical gauges or computer-based prediction systems, the invention reduces manufacturing complexity and cost while maintaining reliable detection functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system provides precise and reliable material level measurements, reducing the risk of 'running dry' by offering accurate volume data and being cost-effective, with the ability to account for ambient temperature and usage patterns, enhancing the reliability of re-supply scheduling.

Implementation Method 1

The sensor element has an optical emitter and an optical receiver positioned to form a triangular vertex with the material surface level within the container

Methodology Applied

Scientific EffectOptical triangulation: Geometry

Data Source

PatentUS7399985B2Optical non-contact sensor for detecting material level in a container

Publication Date: 2008.07.15 DATAONLINE LLC

AI summary

A detection system for determining material level in a container where the container has an opening and an optical window mounted to the opening. A sensor element is mounted to the container adjacent the window. The sensor element has an optical emitter and an optical receiver positioned to form a triangular vertex with the material surface level within the container.