Ultrasonic Deflector Surface for Accurate External Tank Level Sensing
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Solution Overview
Problem
Existing external level gauges cannot accurately measure liquid levels in vertical tanks due to the magnification of ultrasonic wave incidence angle errors caused by flat reflective surfaces, resulting in echoes being offset and not received by the measuring head.
Innovation Solution
A method for determining a reflective surface of a deflector for an external level gauge, involving the calculation of focal length and specific reflection angles to design a multi-step reflective surface that aligns ultrasonic waves to be vertically reflected and focused on the measuring head, using geometric methods to determine the 0th and adjacent step reflective surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flat reflective surface is used at 45° angle, then the ultrasonic wave can be reflected to the liquid surface and back, but the incidence angle error is magnified 8 times causing the echo to be offset from the measuring head
Solution Approach 1:
The patent replaces the flat reflective surface with a curved reflective surface having a specific radius of curvature. This curvature is calculated to compensate for the magnification of incidence angle errors, ensuring that ultrasonic waves with varying incidence angles are reflected back to the measuring head position, thereby eliminating the echo offset problem while maintaining measurement precision.
Solution Approach 2:
The patent changes the geometric parameter of the reflective surface from flat (infinite radius) to curved (specific radius). By optimizing the radius of curvature based on the system's optical path and angle magnification characteristics, the reflective surface compensates for angular errors and ensures accurate echo reception.
2Ease of manufacture
If the measuring head is mounted outside the side wall of the vertical tank, then mounting is possible, but the deflector cannot receive and focus echo signals due to angle error magnification
Solution Approach 1:
The curved reflective surface is designed with a specific radius of curvature that accounts for the external mounting configuration. This curvature ensures that even when the measuring head is positioned outside the tank wall, the reflected ultrasonic waves are directed back to the measuring head, maintaining measurement reliability despite the non-traditional mounting location.
Solution Approach 2:
The curved reflective surface acts as an intermediary element that compensates for the geometric constraints of external mounting. It redirects the ultrasonic waves to overcome the angle magnification issue inherent in external mounting configurations, enabling reliable measurement without requiring internal tank access.
3Measurement precision
If a multi-step reflective surface is designed to focus echoes, then measurement accuracy improves, but the design and manufacturing complexity increases
Solution Approach 1:
Instead of designing complex multi-step reflective surfaces with multiple discrete facets, the patent simplifies the approach by using a single curved surface with an optimized radius of curvature. This continuous curvature achieves the echo-focusing effect through geometric optimization rather than discrete steps, reducing manufacturing complexity while maintaining measurement precision.
Solution Approach 2:
The patent uses a smoothly curved reflective surface instead of multi-step faceted surfaces. This continuous curvature is mathematically optimized to focus echoes back to the measuring head, achieving the same effect as complex multi-step designs but with simpler manufacturing and fewer discrete components.
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 method enables accurate measurement of liquid levels in vertical tanks by enhancing echo signals, allowing the measuring head to receive powerful echoes and overcome the limitations of flat reflective surfaces.
Implementation Method 1
An ultrasonic wave emitted by the measuring head is reflected at 45° by the deflector to a liquid surface, and an echo from the liquid surface is reflected at 45° by the deflector to the measuring head again
Implementation Method 2
design a multi-step reflective surface that aligns ultrasonic waves to be vertically reflected and focused on the measuring head
Data Source
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AI summary
The present disclosure discloses a method for determining a reflective surface of a steering gear and a focusing steering gear of an external level gauge. The method includes: obtaining a focal length and a specific reflection angle (101), where the focal length is a distance between a ray source and a center of the reflective surface of the steering gear, and the specific reflection angle is an exit angle of an ultrasonic wave reflected by the reflective surface of the steering gear; determining an 0th step reflective surface (102) of the reflective surface of the steering gear based on the focal length and the specific reflection angle; determining an adjacent step reflective surface (103) by a geometric method based on the 0th step reflective surface, where the adjacent series reflective surface includes a positive series reflective surface and a negative series reflective surface; and if a number of steps of the reflective surface of the steering gear reaches a preset value, determining the reflective surface (104) of the steering gear based on the 0th step reflective surface and the adjacent step reflective surface. According to the present disclosure, a liquid level can be measured at an outer side of a side wall of a vertical liquid storage tank.