Sonar Transducer System for Liquid Level Measurement Accuracy

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Solution Overview

Problem

Existing sonar-based systems for measuring liquid levels in industrial containers face issues with accuracy due to lower operating frequencies, false signals, harsh environments, and poor signal transfer, leading to frequent malfunctions and inaccurate measurements.

Innovation Solution

A sonar transducer system with multiple transducers and secondary sensors that self-calibrate and process sonar signal signatures to optimize and control processes, using a management module to analyze data and provide real-time insights via a virtual dashboard, improving measurement accuracy and system performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lower operating frequencies are used to transmit acoustic waves through gaseous medium, then the transmitted wave can be reflected at the liquid surface, but the distance measurement accuracy deteriorates

Engineering Contradiction:

Improvesignal reflection capabilityVSAvoiddistance measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent changes the operating frequency parameter from lower frequencies to higher frequencies (e.g., 400 kHz to 1 MHz range), which improves distance measurement accuracy while still maintaining adequate signal reflection capability through the gaseous medium to the liquid surface

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If the detector radiates the transmitted signal in multiple directions, then signal coverage is improved, but the possibility of falsely detecting reflected waves from storage container walls increases

Engineering Contradiction:

Improvesignal coverageVSAvoidfalse signal detection

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent employs a spheroidal or curved array of transducers that focuses the acoustic energy in a controlled manner, providing adequate signal coverage while maintaining a focused beam pattern that reduces false detections from container walls through geometric focusing

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Measurement precision

If damping materials are used to reduce signal dispersion, then signal strength is improved, but device complexity increases

Engineering Contradiction:

Improvesignal strengthVSAvoiddamping material configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses composite material structures for the transducer assembly that inherently provide both signal focusing and damping properties, achieving adequate signal strength without requiring separate damping material configurations, thus maintaining device simplicity

Inventive Principle:

Principle #40Composite materials

4Measurement precision

If bonding agents are used to improve signal transfer within the device, then signal transfer efficiency is improved, but the device becomes more sensitive to harsh environmental conditions

Engineering Contradiction:

Improvesignal transfer efficiencyVSAvoidenvironmental sensitivity

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical bonding agents with electromagnetic coupling methods or direct electrical connections between transducer elements, achieving adequate signal transfer efficiency while eliminating the sensitivity to harsh environmental conditions that affects chemical bonding agents

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

Enhances measurement accuracy and system reliability by eliminating false signals and adapting to harsh conditions, providing real-time and historical data for process optimization and control, while reducing the need for frequent replacements.

Implementation Method 1

the level of a liquid within a storage container may be determined by the concept of echo ranging

Methodology Applied

Scientific EffectEcho ranging: Echo

Implementation Method 2

Once the acoustic wave reaches the surface of the liquid, the wave's frequency is such that it will be reflected back toward the device

Methodology Applied

Scientific EffectAcoustic wave reflection: Reflection

Implementation Method 3

Based on the time it takes the acoustic wave to reach the detector as well as the speed of the acoustic wave within the transmission medium, the distance from the source of the wave to the detector may be calculated

Methodology Applied

Scientific EffectTime of flight measurement: Time of Flight

Data Source

PatentUS11567194B1Sonar transducer system and method of processing data

Publication Date: 2023.01.31 GLUSZYK JOZEF J

AI summary

In a sonar-based transducer system, single or multiple transducers may collect and transmit data to a management module for analysis to optimize and/or control a process. Secondary sensors may provide additional product data for analysis. Historical data may be stored in a data library for future reference. Real time data may be transmitted to a control center via a virtual dashboard.