Product reservoir including intelligent level sensor
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Solution Overview
Problem
Existing chemical dispensing systems fail to provide timely and accurate monitoring of chemical product levels, often resulting in false alarms or failure to notify operators when products are running low due to deposit buildup and corrosive chemical attacks on probe and float mechanisms.
Innovation Solution
A reservoir system with a transceiver that transmits and receives signals to determine the product level by measuring the time of flight of the signal, allowing for accurate volume calculation and alerting operators when levels drop below a threshold, while avoiding direct contact with corrosive substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If probe assemblies with mechanical floats or electrical probes are used to monitor product levels, then the system can detect when product is running low, but the probes and float mechanisms experience deposit buildup and corrosive chemical attacks that impair detection accuracy and reliability over time
Solution Approach 1:
The patent introduces an optical intermediary (light signal) that travels through the container wall and product to detect liquid level, without the sensor itself contacting the corrosive chemical. The optical signal acts as a mediator that transfers information about product level across the container boundary, eliminating the need for direct sensor contact with harmful chemicals.
Solution Approach 2:
The patent replaces mechanical probe assemblies and float mechanisms with an optical detection system. Instead of using mechanical components that physically contact and degrade from chemical exposure, the system uses light transmission properties to detect liquid level, substituting a non-contact optical field-based system for a contact-based mechanical system.
2Measurement precision
If electrical probes are used to detect product level through impedance changes, then the system can provide level indication, but deposit buildup on the probes impairs their ability to detect when product drops low
Solution Approach 1:
The optical signal serves as an intermediary that carries detection information without being contaminated by deposits. The light travels through the container wall and product interface, and the optical properties (transmission, refraction, reflection) provide information about liquid presence without the sensor experiencing deposit buildup that would block or alter electrical probe readings.
3Reliability
If probe assemblies are mounted in containers to monitor product levels, then the system can detect low product conditions, but the probes are directly exposed to corrosive chemicals that attack and degrade the assembly over time
Solution Approach 1:
The container wall acts as a protective intermediary barrier between the optical sensor and the corrosive chemical. The sensor is positioned outside the container, and the wall transmits optical signals while blocking chemical contact, allowing the system to monitor product levels through the wall without the sensor being exposed to degrading chemical environments.
Solution Approach 2:
The patent replaces the mechanical probe assembly that required direct chemical contact with an optical detection system positioned outside the container. This substitution eliminates the physical components that would otherwise be attacked by corrosive chemicals, thereby extending system lifespan and maintaining reliability.
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
This solution provides timely and accurate monitoring of chemical product levels, reducing false alarms and extending the lifespan of monitoring systems by avoiding direct contact with corrosive chemicals, thus ensuring reliable operation and efficient inventory management.
Implementation Method 1
A transceiver coupled to the lid and configured to transmit an output signal and receive a portion of the output signal reflected back to the transceiver as a reflected signal. A computing device operably coupled to the transceiver is configured to determine an amount of a product in the container by comparing a characteristic of the reflected signal to the characteristic of the output signal.
Implementation Method 2
receive a portion of the output signal reflected back to the transceiver as a reflected signal
Data Source
AI summary
Systems, methods, and computer program products for monitoring a level of product in a reservoir of a chemical dispensing system. A lid configured to engage an opening of a container includes a level sensor having a transceiver that transmits an output signal and receives a portion of the output signal reflected back to the transceiver. The level sensor determines an amount of the product in the container by comparing a characteristic of the reflected signal, such as time the reflected signal was received, to the characteristic of the output signal, such as the time the output signal was transmitted. The level sensor may also determine the size of the container based on the reflected signal, and take this size into account when determining the amount of product in the container. The level sensor transmits product level data to a mobile device in response to receiving an interrogation signal therefrom.