Ultrasonic Fill Sensing for Variable Container Dispensing
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Solution Overview
Problem
Existing dispensing systems are unable to automatically fill containers of varying sizes and do not account for contents already present in the container, leading to inefficiencies and inaccurate filling.
Innovation Solution
A sensor system utilizing ultrasound position and fill sensors to detect the container's position and content level, allowing for precise control of the dispensing process, including adaptive threshold and amplification methods to separate rim and liquid signals, ensuring accurate filling regardless of container configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional dispensing systems are used, then the system structure is simple, but the system cannot automatically detect container position and content level, requiring manual operation and leading to inaccurate filling
Solution Approach 1:
The patent replaces mechanical level indication methods with ultrasonic acoustic detection. The ultrasonic sensor emits sound waves and measures the echo time to determine liquid level and container rim position automatically, eliminating the need for mechanical sensors or visual inspection mechanisms.
Solution Approach 2:
The ultrasonic sensor system performs multiple functions: detecting container presence, determining container position, measuring liquid level, and identifying container rim location. This single sensor system replaces what would otherwise require multiple separate detection mechanisms.
2Measurement precision
If conventional dispensing systems are used, then the device complexity is low, but the measurement precision of container position and content level is insufficient
Solution Approach 1:
The system uses ultrasonic acoustic waves instead of mechanical measurement methods to achieve precise detection of container position and liquid level. The time-of-flight measurement of ultrasonic echoes provides high-resolution distance measurements without mechanical contact.
Solution Approach 2:
The system dynamically adjusts detection parameters and processing algorithms based on the detected container type and filling stage. The control unit adapts the ultrasonic detection settings to optimize measurement precision for different container sizes, shapes, and liquid levels.
3Adaptability or versatility
If conventional dispensing systems are used, then the system operation is simple, but the system cannot adapt to containers of varying sizes and existing contents
Solution Approach 1:
The system performs preliminary detection of container presence, size, and pre-existing liquid levels before the dispensing process begins. This initial characterization allows the control unit to automatically adjust dispensing parameters and calculate the appropriate fill amount without requiring manual input.
Solution Approach 2:
The ultrasonic sensor continuously monitors liquid level during dispensing and provides real-time feedback to the control unit. This feedback loop allows the system to automatically adjust the dispensing rate and stop the process when the target fill level is reached, adapting to any container size or pre-existing contents.
4Productivity
If conventional dispensing systems are used, then the filling process is manual and slow, but the productivity is limited by operator speed and accuracy
Solution Approach 1:
The system replaces manual visual inspection and manual operation with automated ultrasonic detection and electronic control. The ultrasonic sensor rapidly measures liquid level and container characteristics, and the control unit automatically manages the dispensing process, significantly increasing filling speed and consistency.
Solution Approach 2:
The ultrasonic sensor operates continuously during the dispensing process, constantly monitoring liquid level and providing real-time data to the control unit. This continuous measurement allows for uninterrupted dispensing at optimal speed, eliminating the stop-start nature of manual monitoring.
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
Enables fully automated, high-precision filling of containers of any size and shape, with the ability to detect and adapt to existing contents, improving fill percentage and user safety by ensuring correct container positioning.
Implementation Method 1
an ultrasound position sensor coupled to the at least one controller a) for emitting a first ultrasound beam towards the container-receiving location, b) for receiving ultrasound echoes indicative of a position of the container relative to the dispenser outlet
Implementation Method 2
for receiving ultrasound echoes indicative of a position of the container
Implementation Method 3
an ultrasound fill sensor coupled to the at least one controller i) for emitting a second ultrasound beam towards the container-receiving location, ii) for receiving ultrasound echoes indicative of the rim and content surface
Implementation Method 4
for receiving ultrasound echoes indicative of the rim and content surface
Data Source
AI summary
Sensor system for acoustic detection in a dispensing system of a container having a rim and content includes at least one controller coupled to the dispensing system for selectively triggering on and off the dispensing system, an ultrasound position sensor coupled to the controller for emitting a first ultrasound beam towards a container-receiving location, for receiving ultrasound echoes indicative of a position of the container relative to a dispenser outlet, and for sending a first signal to the at least one controller indicative of the container position relative to the dispenser outlet, and an ultrasound fill sensor coupled to the at least one controller for emitting a second ultrasound beam towards the container-receiving location, for receiving ultrasound echoes indicative of the rim and content surface, and for sending to the at least one controller a second signal indicative of the position of the content surface relative to the rim.