Retractable Tape Fill Level Sensor for Versatile Reservoir Sensing
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Solution Overview
Problem
Existing level sensors for containers are costly, heavy, and require customization for different fill level specifications, leading to increased time and expense in design and production.
Innovation Solution
A fill level sensor assembly comprising a housing with a retractable tape and sensor, where the sensor is deployed by unrolling the tape from a roller, allowing measurement of a wide range of fill levels with optical or ultrasonic detection, and featuring a lightweight, efficient design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple point level sensors are installed to detect different fill levels, then the measurement precision is improved, but the device complexity and cost increase
Solution Approach 1:
The sensor assembly is segmented into modular components: a housing unit, a tape measure mechanism, and a sensor element. This segmentation allows the system to achieve multiple measurement capabilities through a single modular assembly rather than requiring multiple separate point level sensors, thereby reducing overall device complexity while maintaining measurement precision.
Solution Approach 2:
The sensor assembly is designed with universal functionality to detect multiple fill levels by deploying the tape measure to different positions. The same housing, tape mechanism, and sensor can measure various fill levels by adjusting tape deployment length, eliminating the need for multiple specialized sensors for different detection requirements.
2Measurement precision
If multiple sensors are used to indicate different fill levels, then the measurement precision is improved, but the weight of the reservoir increases
Solution Approach 1:
Multiple sensing capabilities are merged into a single integrated assembly. The housing combines the tape measure mechanism and sensor element into one unified structure, eliminating the need for separate point level sensors. This merging reduces the total weight compared to having multiple independent sensors while maintaining the ability to detect multiple fill levels.
Solution Approach 2:
The sensor assembly achieves multi-functionality through a single universal design that can detect various fill levels by adjusting tape deployment. This universal approach replaces multiple specialized sensors, significantly reducing the overall weight of the sensing system while maintaining comprehensive measurement capability.
3Adaptability or versatility
If the reservoir design is customized for different customer specifications, then the adaptability is improved, but the manufacturing time and cost increase
Solution Approach 1:
The sensor assembly incorporates dynamic adjustability through the tape measure mechanism, allowing the sensing position to be dynamically adjusted to match different customer specifications. This dynamic capability enables the same standardized assembly to adapt to various fill level requirements without requiring custom manufacturing for each application.
Solution Approach 2:
The standardized sensor assembly achieves universality through its ability to detect multiple fill levels via adjustable tape deployment. This universal design allows a single assembly type to serve multiple customer specifications, eliminating the need for custom-designed sensors for different applications and significantly improving manufacturing efficiency.
4Reliability
If traditional point level sensors are used, then the reliability is maintained, but the device complexity and cost increase
Solution Approach 1:
The sensor assembly incorporates self-service features where the tape measure mechanism automatically deploys and retracts the sensor element based on operational requirements. The housing provides self-contained protection and positioning, eliminating the need for complex external mounting and adjustment mechanisms while maintaining reliable sensor operation.
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 assembly provides real-time measurement of a full range of fill levels, is simple to assemble, lightweight, and reduces power consumption, while being less prone to damage and easier to maintain, with the ability to adapt to various fill level requirements.
Implementation Method 1
The measuring means may include a sensor e.g. an optical sensor configured to sense features on the holder and/or the tape indicative of a length of tape deployed
Implementation Method 2
Typical sensors use e.g. an ultrasonic piezoelectric transceiver which transmits a series of ultrasonic pulses
Implementation Method 3
an ultrasonic piezoelectric transceiver which transmits a series of ultrasonic pulses
Data Source
AI summary
A fill level sensor assembly for detecting a level of content in a reservoir, the assembly comprising: a housing configured to be mounted to the reservoir; a tape having a length from a first end to a second end; a holder in the housing for securing the first end of the tape in the housing; a level sensor attached to the second end of the tape; the tape configured to be stowed with the first and second ends and the level sensor in the housing, in a first state, and to be deployed to release the second end and the sensor and a portion of the length of the tape from the housing; and measuring means to measure the length of the released portion of the length of the tape.