Surface Laser Beam for Container Filling Level Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing container filling devices using laser beams for level detection are prone to incorrect measurements due to the need for precise alignment, are affected by container quality issues like scratches, and require multiple sensors, leading to increased device complexity and space requirements.
Innovation Solution
A device utilizing a surface laser beam with a rectangular cross-section that irradiates the entire container neck, allowing for a single compact sensor and reduced alignment requirements, along with optional screens and diaphragms to enhance measurement accuracy for clear and suspended liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a laser beam with a relatively small diameter is used for filling level detection, then the alignment precision between the laser beam and container longitudinal axis must be high, but this increases device complexity and requires additional adjustment devices
Solution Approach 1:
The patent changes the beam diameter parameter from small to large (at least as wide as the container diameter), which fundamentally alters the measurement approach. The large beam diameter allows the entire container cross-section to be illuminated, making the measurement independent of precise alignment while maintaining detection accuracy through overall light intensity evaluation.
Solution Approach 2:
The patent segments the measurement approach by evaluating the overall radiation intensity across the entire container cross-section rather than requiring precise point-by-point alignment. This segmentation of the beam into multiple illumination zones across the container diameter allows any portion to contribute to the measurement, eliminating alignment constraints.
2Measurement precision
If a laser beam with a relatively small diameter is used for filling level detection, then the alignment precision between the laser beam and container longitudinal axis must be high, but this increases the spacing requirements between containers in multi-container devices
Solution Approach 1:
By changing the beam diameter parameter to be large (at least as wide as the container), the patent enables simultaneous illumination of the entire container cross-section. This eliminates the need for precise alignment and reduces the spacing required between containers in multi-container configurations, as the measurement becomes robust to positional variations.
3Measurement precision
If two separate sensor devices are used for each container to detect the laser beam, then the filling level can be detected, but this increases device outlay and requires relatively large spacing between containers
Solution Approach 1:
The patent merges the function of two separate sensor devices into a single sensor by using a large-diameter laser beam that illuminates the entire container cross-section. The single sensor evaluates the overall radiation intensity transmitted through the container, which is sufficient for accurate filling level detection without requiring multiple sensors positioned at specific locations.
Solution Approach 2:
The single sensor device performs multiple functions: it detects light transmitted through different portions of the container cross-section simultaneously and evaluates the overall radiation intensity to determine filling level. This universal approach replaces the need for multiple specialized sensors while maintaining measurement accuracy.
4Reliability
If a conventional laser beam is used, then the measurement signal depends on container quality (blowholes, scratches, surface irregularities), but using a surface beam irradiating the entire container neck makes the signal independent of such defects
Solution Approach 1:
The patent changes the beam configuration parameter from a small-diameter focused beam to a large-diameter surface beam that illuminates the entire container neck. This parameter change distributes the measurement across the whole cross-section, making the signal an average that is insensitive to local defects such as scratches or blowholes, thereby improving 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 more reliable and accurate filling level detection, independent of container defects, with reduced device complexity and space requirements, enabling efficient filling of various container sizes and quantities.
Implementation Method 1
the radiation intensity of a laser beam is thus evaluated, which radiates through the container over the entire diameter of the container neck
Implementation Method 2
When penetrating the container, the laser beam is deflected or refracted to different extents, depending on whether the filling level is at the level of the laser beam or not
Data Source
AI summary
The invention relates to an arrangement (10) for filling containers (1), having a filling device (12) which dispenses a liquid into a container (1) to be filled, wherein the filling level (5) of the liquid is detectable by means of a testing device (25), and wherein the testing device (25) comprises a laser beam source (27) which directs a laser beam onto the container (1), said laser beam passing through the container (1) and being detected on that side of the container (1) that is opposite the laser beam source (27) by means of at least one sensor element (32); provision is made according to the invention for the laser beam directed onto the container (1) to be in the form of a shaped beam (7).