Ultrasonic Bung Waveguide for Accurate Wine Cask Headspace
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Solution Overview
Problem
Current methods for measuring fluid levels in containers, particularly in wine barrels, are inaccurate, prone to false echoes, and require complex calibration, making them cumbersome and time-consuming.
Innovation Solution
A contactless fluid monitoring system using a bung with an elastic body containing a processor, ultrasound transceiver, and transmission waveguide that measures the air gap without contacting the fluid, transmitting data wirelessly for centralized monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic level detectors send bursts of sonic energy through the container wall and liquid, then the level measurement can be obtained, but complex software and calibration are required due to varying attenuation from different wall materials and liquid types
Solution Approach 1:
The patent introduces a dedicated calibration target (reflective surface) as an intermediary element placed at the known bottom position of the container. The ultrasonic transducer measures the time of flight to this calibration target to establish a reference measurement. Subsequent liquid level measurements are taken relative to this calibration reference, eliminating the need for complex calibration procedures for different container materials and liquid types. The calibration target serves as a consistent reference point that mediates between the transducer and the varying environmental factors.
2Reliability
If random sampling of barrels is used to identify abnormal aging conditions, then oxidation and other issues can be detected, but ambient oxygen enters the cask causing deleterious consequences for the wine
Solution Approach 1:
The patent replaces the mechanical/manual sampling method (physically opening the barrel to check contents) with a non-contact ultrasonic sensing system. The ultrasonic transducer mounted on the bung measures liquid level, temperature, and other parameters through the container wall without requiring physical access to the wine. This substitution of measurement methodology eliminates the harmful effect of oxygen exposure during sampling while maintaining reliable detection of aging conditions.
Solution Approach 2:
The monitoring system enables continuous autonomous self-monitoring of barrel conditions without human intervention. The ultrasonic transducer and embedded processor continuously measure parameters and detect abnormal aging conditions automatically. This self-service capability eliminates the need for periodic manual sampling that exposes wine to oxygen, as the system continuously monitors and alerts when intervention is needed, minimizing exposure time.
3Measurement precision
If optical level measurement uses a floatable reflector and light beam, then non-contact measurement is achieved, but the system becomes more complex and may be affected by light absorption and scattering in the liquid
Solution Approach 1:
The patent substitutes the optical measurement system with an ultrasonic acoustic system. Instead of using light beams and floatable reflectors that require complex optical components and are susceptible to light absorption and scattering by the liquid, the invention uses ultrasonic waves that can penetrate the container wall and liquid more reliably. The ultrasonic transducer emits acoustic pulses and measures the time of flight to the liquid surface, providing a simpler and more robust measurement system that is less affected by liquid optical properties.
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
Accurately measures the headspace in containers without physical contact, reducing oxidation risks and simplifying installation, while allowing for easy data collection and real-time monitoring.
Implementation Method 1
Ultrasonic level detectors generally determine the level of the liquid or material by using a transducer to generate a burst of ultrasonic energy towards the surface to be detected
Implementation Method 2
The level of the surface within the tank is determined based upon the amount of time required for the energy burst to travel from the transducer to the surface and back
Implementation Method 3
A transmission waveguide extends from the liquid level sensor to an opening in the bottom of the bung
Implementation Method 4
a bung having an elastic body having a top, bottom, and an internal cavity
Data Source
AI summary
A contactless fluid monitoring system uses a bung with an ultrasound transceiver to measure the headspace in a wine cask or similar container. Ultrasound signals are transmitted through an elongated waveguide so that the signal is in the form of a beam. The elongated transmission waveguide obstructs undesirable intrusion of material into the bung, and filters echo reflections from the ultrasound transceiver so that it receives signals from the same direction at which they are sent. A processor in the bung uses the ultrasound transceiver data, and inclinometer and predetermined information to calculate the headspace within a wine cask. A data collector may wirelessly receive information from a plurality of fluid monitoring bungs and compile and process the data for further analysis.