Ultrasonic Level Sensor Reflector Integration
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Solution Overview
Problem
Existing liquid level measurement devices face challenges in simple installation of reflector and transmitter/receiver devices within the housing, particularly at low fill levels where pulse overlap risks detection errors.
Innovation Solution
The device features a reflector arranged at a distance from the transmitting and receiving device, which deflects ultrasonic pulses parallel to the container bottom, allowing for accurate detection of low fill levels without additional holding devices, using a plane reflector and a reference surface to account for physical property changes in the liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reflector is installed in an angled housing area with additional holding devices, then the ultrasonic pulses can be properly reflected at 90 degrees to the liquid surface, but the device complexity and installation difficulty increase
Solution Approach 1:
The reflector is integrated directly into the housing structure itself, merging the reflector function with the housing. The housing is designed with an angled bottom surface that serves as the reflector, eliminating the need for separate reflector components and holding devices. This reduces device complexity while maintaining the 90-degree reflection angle needed for accurate measurement.
Solution Approach 2:
The housing structure serves multiple functions: it protects the ultrasonic sensor, provides the angled reflection surface, and eliminates the need for separate mounting structures. The angled bottom surface of the housing simultaneously acts as both structural support and acoustic reflector, reducing the overall number of components.
2Measurement precision
If the transmitting and receiving devices are placed very close to the container bottom, then low fill levels can be detected, but the transmitted and received sound pulses may overlap causing detection errors
Solution Approach 1:
Instead of placing the sensor vertically at the bottom, the ultrasonic sensor is positioned horizontally near the bottom, and the housing bottom is angled to reflect pulses vertically upward. This dimensional change in pulse propagation path extends the transit time without increasing the physical distance from the liquid surface, allowing low fill level detection while preventing pulse overlap.
Solution Approach 2:
The angled housing bottom is pre-configured to deflect ultrasonic pulses at a 90-degree angle before they reach the liquid surface. This preliminary deflection action ensures that the pulse path is extended in advance, creating sufficient time separation between transmitted and received pulses even when the liquid level is very low.
3Measurement precision
If an angled tube arrangement with bends is used to extend transit time, then low fill level detection is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The reflection function is merged into the housing structure itself rather than using a separate angled tube arrangement. The housing bottom is formed with an angled surface during the housing manufacturing process, eliminating the need for separate bent tubes or complex assemblies. This maintains transit time extension benefits while simplifying manufacturing.
Solution Approach 2:
The housing is divided into two shell halves that can be separately manufactured and then assembled. This segmentation allows each half to be manufactured using standard processes, and the angled bottom surface is formed as an integral part of the housing assembly, avoiding the need for complex bent tube arrangements.
4Ease of operation
If two shell halves are used to form the housing, then assembly is simplified, but additional sealing and connection requirements increase manufacturing complexity
Solution Approach 1:
The reflector function is merged into the housing structure, eliminating separate components that would require additional sealing and mounting. The angled bottom surface is formed as an integral part of the housing shells, so no separate reflector mounting or sealing is needed, reducing the complexity added by the two-shell design.
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 reliable detection of low fill levels and accounts for density differences and temperature fluctuations, ensuring accurate liquid level measurement without additional retaining elements.
Implementation Method 1
a reflector (3) which reflects the ultrasonic transmission pulses (1) emitted by the transmitting / receiving device (1, 2) in the direction of the liquid surface (7) and which reflects the echo signals (2), which are reflected from the liquid surface (7), in the direction of the receiving device (2)
Implementation Method 2
a transmitting device (1) which emits ultrasonic waves and a receiving device (2) which receives echo signals caused by the ultrasonic transmission pulses of the transmitting device (1)
Implementation Method 3
the transit times of the ultrasonic transmission pulses and the resulting echo signals are evaluated in an evaluation device (8) to determine the level of the liquid (6)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A device for measuring the level of a liquid in a container comprises a transmitter device (1) emitting ultrasound emitter pulses, a receiver device (2) receiving the pulses reflected on the liquid surface, and an evaluation device (8) evaluating the propagation times of the ultrasound emitter pulses and the reflected signals. A reflector (3) is arranged at a defined distance to the transmitter/receiver device (1, 2) and reflects the ultrasound emitter pulses in the direction of the liquid surface and reflects the signals reflected by the liquid surface in the direction of the receiver device (2).