Ultrasonic Sensor Cap for Opaque Container Fill Level Detection
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Solution Overview
Problem
Consumers face challenges in accurately determining the remaining amount of consumable products in opaque containers, leading to laborious, imprecise, and error-prone manual inventory checks, and potential forgetfulness resulting in running out of products at inopportune times.
Innovation Solution
A sensor device integrated into a container cap that electronically measures the remaining liquid level using ultrasonic signals, featuring a transceiver that transmits and receives signals to determine the fill level, and includes mechanisms to mitigate fouling, such as high-frequency signal transmission and passive mechanical structures to reduce interference and improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual checking is used to determine remaining product amount, then no additional device complexity is introduced, but measurement precision and reliability deteriorate due to opacity and human error
Solution Approach 1:
The container cap is designed to perform multiple functions: it serves as both the closure for the container and as a housing for the sensor device. The cap contains a transceiver, processor, and battery, enabling it to function as an autonomous measurement system while maintaining its primary sealing function. This multi-functionality approach resolves the contradiction by integrating the measurement capability into an existing component rather than adding a separate device.
Solution Approach 2:
The sensor device components (transceiver, processor, battery) are nested within the container cap structure. The cap houses the electronic components, which in turn contain the measurement functionality. This nested arrangement allows the measurement system to be embedded within the existing container infrastructure, improving measurement precision without significantly increasing overall device complexity.
2Reliability
If continuous monitoring is implemented to prevent running out of product, then reliability improves, but loss of time and energy increase due to constant measurement and communication
Solution Approach 1:
Instead of continuous monitoring, the sensor device performs measurements at periodic intervals. The processor controls the transceiver to transmit and receive signals at scheduled times, determining remaining product amount only when necessary. This periodic operation maintains reliability by regularly updating product level information while significantly reducing energy consumption compared to continuous monitoring.
Solution Approach 2:
The device incorporates feedback mechanisms where the processor analyzes received signals to determine product level and triggers notifications only when threshold levels are reached. The system provides feedback to the user through wireless communication when reordering is needed, rather than continuously communicating status. This feedback-based approach ensures reliability by alerting users at appropriate moments while minimizing energy loss through selective communication.
3Measurement precision
If high-frequency ultrasonic signals are used to penetrate opaque containers, then measurement precision improves, but object-generated harmful factors increase due to signal interference and fouling
Solution Approach 1:
The transceiver is positioned to transmit ultrasonic signals through the container wall and product to reach a reflector or measurement point. By extracting the measurement function from direct contact with the product interior and using wall penetration, the system achieves measurement precision through opaque containers while minimizing fouling of the sensor itself. The transceiver remains outside the product chamber, separating the measurement capability from the harmful environment.
Solution Approach 2:
The container wall and product medium act as intermediaries that transmit the ultrasonic signals from the transceiver to the measurement point and back. The high-frequency ultrasonic signals penetrate these intermediate layers to achieve accurate fill level detection. This intermediary approach allows measurement precision through opaque materials while the signal path is designed to minimize fouling of the transceiver by keeping it positioned on the container exterior.
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 solution provides accurate, automated, and efficient monitoring of container contents, enabling timely reordering and reducing waste by accurately tracking the remaining product amount, even in opaque containers, and integrating with wireless communication for inventory management.
Implementation Method 1
a sensor device engaged at an opening of a container that electronically determines an amount of content remaining in a container engaged by the sensor device. In some embodiments, the sensor device includes a content level sensor that transmits an ultrasonic signal and measures an amount of time it takes for the ultrasonic signal to bounce off a content remaining in the container and return back to the sensor device
Implementation Method 2
a frequency of the transmitted signal (e.g., equal to or above 80 kHz), and/or a power/amplitude of the transmitted signal selected to allow the transmitted signal to at least in part pass through a content fouling and covering at least a portion of the container
Data Source
AI summary
A sensor device includes a signal transmitting component configured to transmit a signal into a container engaged by the sensor device, wherein a frequency of the signal is selected to allow the signal to at least in part pass through a content fouling at least a portion of the signal transmitting component. The sensor device includes a processor configured to process a received reflected version of the transmitted signal to determine an identifier associated with an amount of content in the container engaged by the sensor device. The sensor device includes a wireless transmitter configured to transmit the identifier associated with the amount of content in the container.