Tank Level Sensor Unit with Auto-Calibration
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Solution Overview
Problem
Existing tank monitoring systems face challenges in accurately measuring the level of materials during the topping-off process, particularly in environments where manual gauging equipment is used, which can be inaccurate and requires intense operator concentration over extended periods.
Innovation Solution
A tank monitoring system that includes a sensor unit capable of being raised and lowered within a tank, using wireless signals to determine the distance between the material and the sensor, and a main unit that calculates the material level using these distances, with auto-calibration features to compensate for variations in the tank medium, enabling precise and automated level measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual gauging equipment is used for tank level measurement, then the system is simple and easy to operate, but the measurement precision deteriorates and operator fatigue increases during extended periods
Solution Approach 1:
The patent replaces manual mechanical gauging equipment with an automated sensor-based system. A sensor unit is lowered into the tank on a cable, and electronic sensors automatically measure the distance to the material surface, eliminating the need for manual operation and significantly improving measurement precision while reducing operator fatigue.
Solution Approach 2:
The system incorporates auto-calibration features where the sensor unit automatically adjusts and calibrates itself during operation. The sensor performs self-diagnosis and calibration routines, eliminating the need for manual calibration by operators and maintaining high measurement precision throughout extended operation periods.
2Productivity
If manual gauging equipment is used, then the device complexity is low, but the productivity deteriorates due to the need for intense operator concentration over several hours
Solution Approach 1:
Manual gauging operations are replaced by an automated sensor system that continuously monitors tank levels without requiring operator attention. The sensor unit is automatically lowered and raised, and measurements are continuously recorded and transmitted, dramatically improving productivity by eliminating the need for operators to maintain intense concentration over several hours.
Solution Approach 2:
The sensor system enables continuous monitoring and measurement operations without interruption. The sensor can continuously track material levels throughout the loading process, providing real-time data for optimization, whereas manual gauging requires periodic interruptions and operator repositioning, reducing overall productivity.
3Measurement precision
If a sensor unit is lowered into the tank for measurement, then the measurement precision is improved, but the device complexity increases due to the need for raising and lowering mechanisms
Solution Approach 1:
The patent replaces complex mechanical raising and lowering mechanisms with a simple cable-based system. The sensor unit is lowered on a cable that can be easily deployed and retracted, eliminating the need for complex winches or motorized mechanisms while maintaining measurement precision. The cable system is operationally simple yet effective for the required measurements.
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 accurate, automated, and continuous monitoring of the material level, reducing operator fatigue and improving loading efficiency and safety by offering high precision and real-time data, even in challenging environments.
Implementation Method 1
The sensor unit transmits wireless signals through the medium to determine the first distance
Implementation Method 2
The ultrasonic sensor sends an ultrasonic wave to the surface of a granule in a silo bin to detect the distance to the surface
Data Source
Figure 1~2
Figure 3~6B
Figure 4~7
AI summary
A method includes lowering (902) a sensor unit (204) in a tank (102), where the tank is capable of receiving a material (114). The method also includes determining (908) a first distance between the material and the sensor unit and determining (906) a second distance between the sensor unit and a main unit (202) that lowers the sensor unit. In addition, the method includes determining (910) a level of the material in the tank using the first and second distances. The method could further include calibrating (904) the sensor unit to compensate for variations in a medium within the tank, where the sensor unit transmits wireless signals through the medium to determine the first distance. Determining the first distance could include using an ultrasonic measurement technique, and determining the second distance could include using a non-contact servo measurement technique.