Ultrasonic Level Sensor Dynamic Interval Switching
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Solution Overview
Problem
Existing level sensors for containers are ineffective in monitoring liquid levels during filling, as they require frequent manual visual inspection, which is hazardous and inaccurate, and they often consume excessive power, leading to short battery life and potential false alarms.
Innovation Solution
A level sensor system that alternates between long and short measurement intervals based on liquid level changes, using ultrasonic transducers and radio transmitters to minimize power consumption and provide real-time monitoring, with a visual display for continuous operation during filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the monitoring unit is operated periodically with long time intervals to conserve power, then battery life is extended, but the system cannot monitor liquid level during filling operations
Solution Approach 1:
The monitoring unit dynamically adjusts its operating interval based on detected liquid level changes. When a level change is detected (indicating filling or draw-off), the system switches to a second operating mode with shorter time intervals to provide continuous monitoring. During stable periods, it operates in the first mode with longer intervals to conserve battery power, thus resolving the contradiction between battery life and monitoring reliability.
2Productivity
If the monitoring unit operates at short time intervals to provide continuous monitoring, then real-time level data is available, but power consumption increases significantly
Solution Approach 1:
The system implements periodic operation with two distinct time intervals. The first operating mode uses a first time interval (e.g., 1 hour or greater) for routine monitoring to minimize power consumption. The second operating mode uses a second time interval (e.g., 1-10 seconds) only when triggered by detected level changes. This periodic switching between intervals resolves the contradiction by providing high-frequency monitoring only when necessary.
3Use of energy by moving object
If manual visual inspection is used to monitor liquid level during filling, then no additional power is required, but the process is hazardous and inaccurate
Solution Approach 1:
The monitoring unit automatically detects liquid level changes using ultrasonic transducers and triggers appropriate monitoring modes without requiring manual intervention. The system self-adjusts its operating interval based on detected conditions, eliminating the need for hazardous manual visual inspection while maintaining low power consumption during stable periods. This resolves the contradiction by providing automated, safe, and accurate monitoring with minimal power usage.
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 system extends battery life, reduces false alarms, and allows for accurate real-time monitoring of liquid levels during filling, enhancing safety and efficiency by minimizing power usage and providing continuous visual updates.
Implementation Method 1
an ultrasonic transducer which transmits ultrasonic signals to the surface of the liquid in the tank and monitors signals reflected from the surface of the liquid
Implementation Method 2
By determining the time of flight of the signal, in other words, the time taken by a signal from the time it is transmitted until the reflection of the signal from the surface of the liquid is received by the transducer
Data Source
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AI summary
Apparatus (1) for monitoring liquid level in a tank comprises a battery powered monitoring unit (2) for mounting in or on the tank, and a remote display unit (3) which is mains powered. The monitoring unit (2) comprises a microcontroller (8) which operates the monitoring unit (2) alternatively in one of a first operating mode and a second operating mode. During the first operating mode an ultrasonic transducer (7) determines the liquid level at third predefined time intervals of fifteen seconds and operates a radio transceiver (10) to transmit a signal indicative of the liquid level at first predefined time intervals of one hour to the display unit (3). For so long as the microcontroller (8) determines that the liquid level is constant or falling at a normal draw-off rate, the monitoring unit (2) is operated in the first operating mode. On the microcontroller (8) determining that the liquid level is falling at a rate greater than a normal draw-off rate or is rising, the monitoring unit (2) is operated in the second operating mode. In the second operating mode the microcontroller (8) operates the ultrasonic transducer (7) to determine the liquid level at second predefined time intervals of half of one second and operates the transceiver (10) to transmit a signal indicative of the liquid level at the second predefined time intervals for reception by the remote display unit (3). A visual display screen (15) in the remote unit (3) displays a graphical representation of the liquid level in the tank. The monitoring unit (2) may be provided with a visual display screen which would also display a graphical representation of the liquid level. The monitoring unit (2) may be operated in a third operating mode for determining if signals received from the ultrasonic transducer (7) are spurious signals.