Self-Calibrating Base Station for Tank Volume Measurement
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Solution Overview
Problem
Current tank calibration methods, such as the optical reference line method, are inefficient and prone to inaccuracies due to reliance on manual measurements and limited data points, which can lead to unreliable volume calculations and pose safety risks for operators.
Innovation Solution
A self-calibrating system with a mechanism for adjusting a platform's level and alignment, using light-emitting devices and sensors to ensure precise alignment and data correction, allowing for automated and accurate tank volume measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used in tank calibration, then device complexity is reduced, but measurement precision and reliability deteriorate due to human error and limited data points
Solution Approach 1:
The base station automatically performs alignment verification by rotating the platform 180 degrees and using level sensors to detect alignment errors. The system self-corrects alignment without requiring manual intervention, thereby improving measurement precision while keeping the system relatively simple.
Solution Approach 2:
Level sensors provide feedback on the alignment of the platform and light-emitting device. This feedback is used to automatically adjust and verify alignment, ensuring high measurement precision through iterative correction rather than complex manual procedures.
2Measurement precision
If automated alignment mechanisms are implemented, then measurement precision improves, but device complexity and manufacturing cost increase
Solution Approach 1:
Manual alignment procedures are replaced with an automated system using level sensors and rotational mechanisms. The sensors electronically detect alignment status and trigger automated adjustments, improving precision while using standard off-the-shelf components that simplify manufacturing.
3Reliability
If multiple sensors and adjustment mechanisms are added to improve reliability, then calibration accuracy improves, but ease of operation deteriorates due to complex setup procedures
Solution Approach 1:
The system automatically performs alignment verification by rotating the platform and using level sensors to detect and correct alignment errors. This self-service capability improves reliability without requiring operators to perform complex manual alignment procedures.
Solution Approach 2:
The system performs preliminary alignment verification automatically before taking measurements. The base station rotates the platform and checks alignment using level sensors, ensuring reliable measurements are taken only when properly aligned, without requiring manual preparation.
4Productivity
If manual alignment verification is performed, then device complexity is minimized, but productivity deteriorates due to time-consuming calibration procedures
Solution Approach 1:
Manual alignment verification is replaced with an automated electronic system using level sensors and rotational mechanisms. The sensors automatically detect alignment status and trigger corrections, significantly increasing calibration speed while using standard components that don't overly complicate the device.
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 consistent and accurate calibration of tank volumes, reducing human error and improving safety by automating the alignment and measurement process, resulting in more reliable and efficient tank calibration.
Implementation Method 1
a light-emitting device with beam-like optics (laser, diode, etc.) mounted to the platform
Data Source
AI summary
A self-calibrating system, apparatus, and method for accurately measuring a volumetric capacity of a tank. The system, apparatus and method comprise: a mechanism that adjusts a level of a platform; a light-emitting device with beam-like optics (laser, diode, etc.) mounted to the platform; mechanism for adjusting alignment of the light-emitting device with respect to the platform; a mechanism for rotating the platform by variable angles, including by 180-degrees; one or more level sensors (such as, for example, spirit levels, tilt sensors, or other devices) that provide feedback on the alignment of the platform normal to the gravity vector.