Deployable Tape Fill Level Sensor for Lightweight Reservoir Sensing
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Solution Overview
Problem
Existing fill level sensors for containers are costly, heavy, and require customization for different fill level specifications, leading to increased time and expense in design and production.
Innovation Solution
A fill level sensor assembly comprising a housing, a tape with a secured end and a sensor at the other end, deployed from the housing to measure the length of the tape extended into the container, using a roller mechanism and optical or hole-based measurement to determine the fill level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple point level sensors are installed to detect different fill levels, then the fill level detection capability is improved, but the cost and weight of the reservoir increase
Solution Approach 1:
The single sensor is segmented in time rather than space - it measures different fill levels at different times by deploying to different positions along the tape length, replacing the need for multiple simultaneous sensors
Solution Approach 2:
The sensor system is made dynamic through the deployable tape mechanism, allowing a single sensor to occupy multiple positions sequentially rather than requiring multiple fixed sensors simultaneously
2Measurement precision
If multiple point level sensors are installed to detect different fill levels, then the fill level detection capability is improved, but the cost of the reservoir increases
Solution Approach 1:
A single sensor assembly performs the function of multiple sensors by deploying to different positions along the tape, making the system universal for detecting any fill level within the measurable range
Solution Approach 2:
The measurement function is segmented across time and position rather than requiring multiple simultaneous sensor units, reducing component count and manufacturing cost
3Measurement precision
If custom reservoir designs are created for different customer fill level specifications, then the detection accuracy for specific applications is improved, but the design time and cost increase
Solution Approach 1:
The system adapts to different applications dynamically through software configuration of measurement ranges and thresholds rather than requiring physical redesign, enabling rapid customization
Solution Approach 2:
A single universal sensor assembly design can serve multiple applications with different fill level requirements by adjusting deployment distance and measurement parameters, eliminating the need for custom designs
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 assembly provides a simple, lightweight, efficient, and reliable solution for measuring a wide range of fill levels with reduced power consumption and minimal damage risk, suitable for various applications.
Implementation Method 1
a holder in the housing for securing the first end of the tape in the housing; the tape configured to be stowed with the first and second ends and the sensor in the housing, in a first state, and to be deployed to release the second end and the sensor and a portion of the length of the tape from the housing
Implementation Method 2
The measuring means may include a sensor e.g. an optical sensor configured to sense features on the holder and/or the tape indicative of a length of tape deployed, e.g. markings on the holder and/or on the tape, or holes along the length of the tape
Implementation Method 3
Typical sensors use e.g. an ultrasonic piezoelectric transceiver which transmits a series of ultrasonic pulses. A microcontroller within the PLS monitors for the return of the pulses.
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3~4
AI summary
A fill level sensor assembly for detecting a level of content in a reservoir (1), the assembly comprising: a housing (104) configured to be mounted to the reservoir; a tape (102) having a length from a first end (102a) to a second end (102b); a holder (103) in the housing for securing the first end of the tape in the housing; a level sensor (101) attached to the second end of the tape; the tape configured to be stowed with the first and second ends and the level sensor in the housing, in a first state, and to be deployed to release the second end and the sensor and a portion of the length of the tape from the housing; and measuring means (107, 108) to measure the length of the released portion of the length of the tape.