Tank Level Monitoring With Dynamic Sampling for Misfill Detection
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Solution Overview
Problem
Existing systems fail to effectively detect operator errors when filling tanks, leading to potential misfilling or harmful mixing of products, due to the risk of inadvertently filling the wrong tank.
Innovation Solution
A level measurement system with adjustable measurement frequencies and dual wireless communication modes, allowing for increased frequency during potential filling operations and low power consumption during idle periods, combined with short-range communication for real-time detection of operator errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the level measurement system continuously measures at high frequency to detect operator errors, then the detection capability is improved, but the energy consumption increases
Solution Approach 1:
The measurement frequency is made dynamic rather than static. The system automatically adjusts the measurement frequency based on operational context: high frequency during filling operations to detect errors, and low frequency during normal operation to conserve energy. This dynamic adaptation resolves the contradiction between continuous monitoring and energy conservation.
Solution Approach 2:
The system changes the measurement parameter (frequency) based on detected conditions. When a filling operation is detected, the measurement frequency parameter is increased; otherwise, it is decreased. This parameter change allows the system to optimize both detection capability and energy consumption at different operational states.
2Speed
If the measurement frequency is increased to detect operator errors in real-time, then the response time is improved, but the energy consumption increases
Solution Approach 1:
The system uses periodic measurements with variable periods. During normal operation, measurements are taken at longer intervals (lower frequency). During filling operations, the period is shortened (higher frequency) to improve detection speed. This periodic action with adaptive timing resolves the contradiction between fast response and energy consumption.
3Reliability
If the system monitors all tanks continuously at high frequency, then the detection capability is improved, but the loss of energy increases
Solution Approach 1:
The system applies different measurement qualities (frequencies) to different tanks based on local conditions. When a filling operation is detected at one tank, only that tank's measurement frequency is increased, while other tanks continue at lower frequencies. This localized quality adjustment resolves the contradiction between comprehensive monitoring and energy loss.
Data Source
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AI summary
A level measurement system, for measuring the level of a product in a tank being monitored by an asset management system, the level measurement system comprising: level sensing circuitry for measuring the level of the product; wireless communication circuitry for wireless communication; and a controller for controlling operation of the level measurement system, the controller being configured to: control the sensing circuitry to periodically measure the level of the product with a first measurement frequency; transmit a signal indicative of the measured level of the product, using the wireless communication circuity; receive, from the asset management system using the wireless communication circuitry, an indication of a work order for filling a neighboring tank within a predefined distance from the tank; and control, after having received the indication of the work order, the level sensing circuitry to periodically measure the level of the product with a second measurement frequency, higher than the first measurement frequency.