Self-aligning Sensor Housing for Silo Level Measurement
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Solution Overview
Problem
Existing monitoring systems for silo contents face issues with particle obstruction during refilling and require precise sensor orientation, leading to inaccurate or unavailable measurements due to suspended particles and deviation from a vertical signal path.
Innovation Solution
A sensing apparatus with a pivotally connected housing and sensor, where the center of mass is below the pivot axis, allowing the sensor to self-align vertically and maintain orientation, and a cover to protect the sensor from particles, ensuring accurate measurements without manual calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is positioned to measure substance level using sonar or lidar, then the height or level of the substance can be measured, but particles suspended in the air during refilling will attach to the sensor and obstruct it, preventing proper emission and reception of signals
Solution Approach 1:
The sensor is extracted from the direct path of particle deposition by positioning it on the roof of the silo rather than inside the silo chamber. The sensor measures substance level from above through the roof opening, eliminating exposure to particles that settle during refilling operations.
Solution Approach 2:
The roof of the silo acts as an intermediary barrier between the sensor and the particles suspended in the air during refilling. The sensor is positioned on the roof, using the roof structure itself as a protective intermediary that prevents particle attachment while allowing the sensor to function.
2Measurement precision
If the signal path is oriented vertically perpendicular to the substance surface, then the distance measurement is most accurate with the shortest travel distance, but any deviation causes the reflected signal to bounce outside the sensing range or against walls, increasing measured distance and reducing precision
Solution Approach 1:
The positioning system is segmented into multiple components: the roof mounting location, the vertical opening alignment, and the sensor orientation. This segmentation allows each component to be independently optimized - the roof provides a stable mounting platform, the opening ensures vertical alignment, and the sensor is positioned to emit signals along the vertical axis.
Solution Approach 2:
The sensor is positioned at the roof level, creating an equipotential reference point for vertical measurement. By establishing the measurement origin at the roof opening and measuring downward along the vertical axis, the system ensures consistent gravitational reference and eliminates angular deviations that would occur with non-vertical positioning.
3Measurement precision
If manual positioning and calibration are required to ensure the sensor is properly oriented vertically, then measurement accuracy can be maintained, but the installation becomes complex and time-consuming
Solution Approach 1:
The roof structure itself provides the self-aligning mechanism for vertical sensor positioning. By mounting the sensor on the roof and orienting it downward through the roof opening, the gravity vector and the roof geometry automatically ensure vertical alignment without requiring manual calibration or complex positioning equipment.
Solution Approach 2:
The roof serves multiple functions simultaneously: it provides structural support for mounting the sensor, acts as a protective barrier against particles, defines the vertical measurement axis through its opening, and provides a stable platform for sensor installation. This multi-functionality eliminates the need for separate positioning and calibration mechanisms.
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 apparatus provides reliable and accurate measurements of silo content levels by maintaining the sensor in a vertical orientation and protecting it from obstructions, reducing errors and installation complexity.
Implementation Method 1
the sensor is configured for providing a signal downwardly towards a top surface of the substance along a linear signal path such that the signal is reflected on the top surface of the substance and for receiving the reflected signal
Implementation Method 2
the center of mass of the sensing assembly being located below the pivot axis to urge the housing towards an operative position by gravity
Data Source
AI summary
A sensing apparatus for monitoring a substance contained in a storage building, the apparatus comprising: a mounting bracket configured to be secured to a roof of the storage building; a sensing assembly mounted to the mounting bracket, the sensing assembly including: a sensor for measuring a parameter of the substance in the storage building when the sensor is in a measuring orientation; and a housing for housing the sensor, the housing being pivotably connected to the mounting bracket and being freely pivotable relative to the mounting bracket about a pivot axis, the housing being orientable in an operative position in which the sensor is in the measuring orientation to allow the sensor to measure the parameter of the substance, the sensing assembly having a center of mass located below the pivot axis such that the housing is urged towards the operative orientation by gravity.