Ultrasonic Liquid Level Sensor in Narrow Pipes
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Solution Overview
Problem
Existing liquid level measurement methods for absorption fields and groundwater wells are cumbersome, prone to fouling, and provide unreliable or snapshot measurements, especially in narrow diameter pipes, lacking a reliable non-contact solution.
Innovation Solution
A non-contact liquid level measurement device using an ultrasound sensor assembly within a seamless pipe to measure liquid levels by transmitting and receiving ultrasound energy waves, with optional mechanical backup sensors and wireless communication for remote monitoring, ensuring accurate and continuous level detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical float switches or pressure transducers are used to measure liquid levels, then liquid level can be sensed, but the sensors are prone to fouling from biological matter buildup and become unreliable
Solution Approach 1:
The patent replaces mechanical float switches and pressure transducers with an ultrasonic sensor system that uses sound waves to measure liquid level. The ultrasonic sensor transmits acoustic energy through the air in the inspection port and detects the reflected echo from the liquid surface, eliminating direct contact between the sensor and wastewater, thereby preventing fouling and improving reliability
Solution Approach 2:
The patent introduces air as an intermediary medium between the sensor and the liquid. The ultrasonic sensor measures liquid level by transmitting sound waves through the air column in the inspection port, using the air-liquid interface as a mediator to detect liquid level without the sensor touching the contaminated liquid
2Measurement precision
If measurement sticks are inserted into inspection ports for liquid level measurement, then liquid level can be measured, but the process is time consuming and only provides snapshot measurements
Solution Approach 1:
The patent replaces manual mechanical measurement sticks with an automated ultrasonic sensing system that continuously or periodically measures liquid levels remotely. The system provides real-time or near-real-time measurements without requiring physical insertion or removal of measurement devices, dramatically reducing measurement time and enabling continuous monitoring
Solution Approach 2:
The ultrasonic sensor system operates autonomously within the inspection port, continuously monitoring liquid levels without human intervention. The sensor automatically transmits ultrasonic pulses, detects echoes, calculates liquid level, and can trigger alarms or notifications when thresholds are exceeded, eliminating the need for manual measurement operations
3Reliability
If large diameter tubes are used to accommodate mechanical float switches, then float switches can operate, but the device complexity and installation difficulty increase
Solution Approach 1:
The patent replaces mechanical float switches requiring large diameter tubes with compact ultrasonic sensors that can operate in narrow diameter inspection ports. The ultrasonic sensor emits sound waves through the air column, requiring only enough space for the sensor housing and acoustic path, significantly reducing the required tube diameter and simplifying installation in existing narrow inspection ports
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 quick, accurate, and continuous monitoring of liquid levels, preventing overloading and contamination, with historical data logging and alarm notifications, while avoiding cross-contamination and interference.
Implementation Method 1
a non-contact sensor assembly disposed within said pipe at a location spaced above the liquid, said sensor assembly sensing the level of said liquid and generating output representative of said liquid level
Implementation Method 2
measuring the time taken for the transmitted ultrasound energy wave to travel to the surface of the liquid and reflect back to the sensor assembly
Data Source
AI summary
A liquid level measurement device comprises a generally seamless pipe for insertion into an installation in which liquid level is to be monitored and a non-contact sensor assembly disposed within the pipe at a location spaced above the liquid. The sensor assembly senses the level of the liquid and generates output representative of the liquid level.