Ultrasonic Debris Level Sensor for Vacuum Loader Tanks
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Solution Overview
Problem
Current methods for determining debris level in vacuum loader trucks are inadequate due to limitations in sensing range, susceptibility to environmental conditions, and effectiveness in handling various debris types, including liquids, solids, and mixtures, with existing solutions like floating balls, paddle wheel switches, and sight glasses being prone to damage and inefficiency.
Innovation Solution
A debris level monitoring system that uses a debris level sensor, such as an ultrasonic sensor, to generate a sensing beam that reflects off the top surface of debris within the storage tank, with a control module calculating the debris level based on the time delay and speed of the beam, and modifying the truck's operation accordingly, including adjusting the blower and providing indicators to the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a floating ball is used to indicate debris level, then the debris level can be indicated, but the sensor has limited range and is susceptible to being buried by dry material
Solution Approach 1:
The patent replaces the mechanical floating ball system with an ultrasonic sensing system that uses sound waves to detect debris level. The ultrasonic sensor emits sound pulses and measures the time for echo return, eliminating the need for physical contact with debris and avoiding burial issues while maintaining measurement capability across the full tank range.
2Measurement precision
If a paddle wheel switch is used, then one discrete level can be indicated, but it indicates only one level not a range and is subject to sticking and damage
Solution Approach 1:
The patent replaces the mechanical paddle wheel switch with an ultrasonic sensing system that detects debris level remotely using sound wave reflection. This eliminates mechanical contact with flying debris, preventing sticking and damage while providing continuous level measurement across the entire range rather than a single discrete point.
3Measurement precision
If a sight glass is used to view inside the tank, then the debris level can be observed, but it quickly gets dirty and becomes ineffective and cannot be read remotely
Solution Approach 1:
The patent replaces the optical sight glass system with an ultrasonic sensing system that electronically measures and transmits debris level data to remote displays. This eliminates the need for direct visual observation through dirty glass and enables remote monitoring from the operator's position without line-of-sight requirements.
4Measurement precision
If traditional sensing methods are used, then debris level can be detected, but the sensor is exposed to severe conditions including vibrations, high winds, and dirt contamination
Solution Approach 1:
The patent uses an ultrasonic sensing system that measures debris level remotely by emitting sound waves and detecting echoes from the debris surface. The sensor remains mounted on the tank structure away from direct exposure to severe conditions, using acoustic field interaction rather than physical contact with debris, thereby maintaining measurement precision while reducing environmental damage.
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 determines the debris level in the storage tank, enabling efficient operation and preventing overfilling, while also monitoring air filter status and particulate matter, ensuring reliable and remote operation of the vacuum loader truck.
Implementation Method 1
A debris level sensor is mounted near the top end of the storage tank. The debris level sensor generates a sensing beam toward the top surface of the debris accumulated within the storage tank. The sensing beam is reflected off of the top surface of the accumulated debris and the reflected beam is sensed by the debris level sensor.
Implementation Method 2
The control module determines the time delay between the generation of the sensing beam and the detection of the reflected beam. A processor contained within the control module calculates the level of debris within the storage tank based upon the time delay and the speed of the sensing beam.
Data Source
AI summary
A vacuum loader truck that includes a storage tank that can be loaded and unloaded with debris. The vacuum loader truck includes a debris level sensor that generates a sensing beam to detect the level of debris within the storage tank. The level of debris within the storage tank is determined by a control module and displayed. The debris level sensor may be an ultrasonic sensor that generates a sensing beam that is reflected off of the top surface of the debris within the storage tank. The control module determines the height of the debris within the storage tank based upon the time delay between the generation of the sensing signal and the reflected signal. The control system further includes a particle sensor to determine whether particles are entrained in the airflow from the storage tank. A pair of pressure sensors are located on opposite sides of an air filter to sense the differential pressure across the air filter. Based upon the signals from the debris level sensor, the pressure sensors and the particle sensor, the control module can control the operation of the vacuum loader truck.