Ultrasonic Sensor Device for Automated Container Fill-Level Detection

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Solution Overview

Problem

Manual inventory processes for determining the remaining content in product containers, such as food and beverage bottles, are laborious, imprecise, and error-prone, particularly in commercial settings where time and resources are valuable.

Innovation Solution

A sensor device, like a container cover with a built-in ultrasonic sensor, measures the liquid level by transmitting and receiving signals to accurately determine the fill level, with configuration options for different container types and wireless communication for data transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual visual inspection is used to determine remaining content in containers, then no additional equipment is needed, but measurement precision and reliability deteriorate

Engineering Contradiction:

Improveprecision of remaining content measurementVSAvoidcomplexity of measurement system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual visual inspection with an automated optical sensor system. The sensor device includes a light source and photodetector that automatically measure liquid level through optical reflection, eliminating the need for human visual assessment and significantly improving measurement precision while reducing subjectivity and error.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor device is designed to be attached to the container itself, using the container's existing structure (opening, rim) to perform measurements. The device self-calibrates by detecting the container opening position and automatically determines liquid level without requiring external measurement equipment or manual intervention.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual inventory processes are used, then no additional equipment is needed, but productivity and time efficiency worsen

Engineering Contradiction:

Improveinventory checking speedVSAvoidtime spent on inventory checking

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The sensor device enables continuous monitoring of liquid levels by automatically taking measurements at predetermined intervals or when triggered by specific events (opening, closing, pouring). This eliminates the need for periodic manual inventory checks and allows for real-time tracking of content depletion, significantly improving productivity and reducing time loss.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The automated sensor system replaces manual inventory checking processes entirely. The device automatically measures and records liquid levels, transmitting data wirelessly to inventory management systems, thereby eliminating the time-consuming manual processes of visual inspection, recording, and data management.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If manual visual inspection is used, then device complexity remains low, but reliability and error rate worsen

Engineering Contradiction:

Improvereliability of inventory dataVSAvoidcomplexity of measurement system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces unreliable manual visual inspection with an automated optical measurement system that objectively detects liquid levels. The sensor device eliminates human factors such as fatigue, subjective judgment, and visual estimation errors, providing consistent and reliable measurements that can be automatically recorded and transmitted for inventory management.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor device incorporates feedback mechanisms where measurement results are automatically transmitted to inventory management systems. The system can trigger alerts when liquid levels reach predetermined thresholds, enabling proactive inventory management and reducing the risk of stockouts or wasted products due to unreliable manual monitoring.

Inventive Principle:

Principle #23Feedback

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 sensor device provides precise and efficient measurement of the remaining content, reducing human error and labor costs by automating the inventory process, enabling better inventory management and reordering.

Implementation Method 1

measures the liquid level by transmitting and receiving signals

Methodology Applied

Scientific EffectUltrasonic: Ultrasound

Implementation Method 2

measures the liquid level by transmitting and receiving signals

Methodology Applied

Scientific EffectEcho: Echo

Data Source

PatentUS10591345B2Sensor device configuration

Publication Date: 2020.03.17 NECTAR INC

AI summary

A sensor device includes an interrogation signal transmitter configured to transmit an interrogation signal to determine an identifier associated with an amount of content included in a container engaged by the sensor device. The interrogation signal transmitter is configured to transmit the interrogation signal that travels through air included in the container to reflect off the content in the container.