Ultrasonic Level Sensor Horizontal Probe Design
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Solution Overview
Problem
Existing ultrasonic sensors for liquid level measurement in vessels have a dead zone near the bottom due to transducer housing height and ringing issues, preventing accurate measurement close to the vessel bottom, and are prone to false indications from liquid accumulation.
Innovation Solution
An ultrasonic sensor design with a transducer mounted at the lower end of a tubular probe that transmits energy horizontally across the probe, eliminating the need for a housing and reducing the dead zone by using an angled reflector element to direct energy parallel to the liquid surface, and optionally incorporating a reflective pin for velocity compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transducer is mounted in a housing that extends from the end of the tube within the probe, then the transducer is protected and structurally supported, but the housing creates a dead zone that prevents measurement of liquid level close to the vessel bottom
Solution Approach 1:
The patent removes the transducer housing from the probe structure, extracting the protective function while eliminating the dead zone problem. The transducer is mounted directly at the lower end of the probe without an extending housing, allowing measurement down to the probe tip.
Solution Approach 2:
The patent changes the transmission direction from vertical (along the probe axis) to horizontal (transverse to the probe axis). This dimensional change allows the ultrasonic beam to travel parallel to the liquid surface, eliminating the dead zone created by vertical housing extension.
2Device complexity
If the transducer transmits ultrasonic energy vertically upward along the probe longitudinal axis, then the measurement setup is simple, but transducer ringing creates a dead zone that prevents accurate measurement in the region between the housing and the probe
Solution Approach 1:
The patent changes the ultrasonic energy transmission from vertical (along the probe axis) to horizontal (transverse to the probe axis). This allows the beam to travel parallel to the liquid surface, eliminating the dead zone caused by transducer ringing while maintaining structural simplicity.
Solution Approach 2:
The patent introduces an angled reflector element as an intermediary to redirect the horizontally transmitted ultrasonic energy upward toward the liquid surface and back to the transducer, enabling the horizontal transmission configuration to work effectively for vertical level measurement.
3Strength
If the transducer housing extends into the vessel to provide structural support, then the transducer is securely mounted, but liquid may accumulate on the top portion of the housing causing false indications
Solution Approach 1:
The patent removes the transducer housing from the probe structure, eliminating the liquid accumulation problem that causes false indications. The transducer is mounted directly at the probe end without an extending housing that could trap liquid.
4Measurement precision
If a well is constructed at the vessel bottom to accommodate the transducer housing, then the dead zone measurement problem is eliminated, but the vessel construction cost and mounting difficulty increase
Solution Approach 1:
The patent changes the ultrasonic transmission from vertical to horizontal, eliminating the need for a well structure. The transducer transmits energy parallel to the liquid surface, allowing accurate measurement down to the probe tip without requiring vessel modification.
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 accurate liquid level measurement closer to the vessel bottom with a reduced dead zone of ¼″ and improved reliability by eliminating the need for a well and compensating for changes in ultrasonic energy velocity.
Implementation Method 1
A transducer that converts electrical energy to ultrasonic energy is mounted at or near the lower end of the tube
Implementation Method 2
The ultrasonic energy is transmitted from the bottom end of the probe and is reflected from the liquid surface and received back at the transducer
Implementation Method 3
The upwardly transmitted ultrasonic energy is reflected from the interface of the liquid 14 and air, or other gas, downwardly back to the transducer 26
Implementation Method 4
The transducer converts the received ultrasonic energy back into electrical energy signals that are supplied to the electronics module 34
Data Source
AI summary
An ultrasonic sensor for measuring the level of liquid in a vessel has an elongated tubular probe, a tube within the probe, and a transducer that converts electrical energy to ultrasonic energy mounted at or near one end of the tube so as to transmit ultrasonic energy horizontally across the probe. An element having a surface that reflects ultrasonic energy is at an angle, preferably of about 45°, to the probe longitudinal axis opposite to an ultrasonic energy emitting part of the transducer to reflect ultrasonic energy received from the transducer upwardly in the probe to an air-liquid interface from which it is downwardly reflected to the angled reflector element that directs the energy reflected from the interface back to the transducer for conversion to an electrical signal that is used by an electronic module to measure the liquid level in the probe which is the liquid level in the vessel.