Ultrasonic Sensor Device for Automated Container Content Level Measurement
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Solution Overview
Problem
Manual inventory processes for determining the remaining content in product containers, such as food and beverages, are laborious, imprecise, and error-prone, especially in commercial settings where time and resources are valuable.
Innovation Solution
A sensor device, like a container cover with a built-in content level sensor, uses ultrasonic signals to measure the liquid level in containers, transmitting data wirelessly and adapting its configuration based on container type to provide accurate and efficient content measurement.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent replaces manual visual inspection with an automated sensor device that uses ultrasonic or optical signals to measure the distance to the liquid surface. This substitution of mechanical/manual measurement with physical field-based measurement (acoustic or electromagnetic waves) achieves precise automated measurement without requiring complex manual procedures
Solution Approach 2:
The patent introduces an intermediary sensor device positioned between the user and the container contents. This intermediary device contains a signal transmitter and receiver that indirectly measure liquid level by detecting the distance to the liquid surface, providing accurate measurements without direct contact with the liquid and eliminating the need for manual visual estimation
2Productivity
If manual inventory processes are used, then no additional equipment is needed, but productivity and time efficiency worsen
Solution Approach 1:
The sensor device performs self-service by automatically measuring and reporting liquid levels without requiring human intervention. The device autonomously transmits interrogation signals, receives echoes, calculates distances, and communicates measurements to remote systems, enabling continuous automated inventory monitoring that eliminates time-consuming manual processes
Solution Approach 2:
The patent implements feedback mechanisms where the sensor device continuously monitors liquid levels and transmits data to remote systems or displays. This real-time feedback enables automated inventory management, allowing users to receive immediate information about remaining content and trigger replenishment actions before stockouts occur, significantly improving productivity
3Reliability
If manual inventory methods are used, then device complexity remains low, but reliability and error rate worsen
Solution Approach 1:
The patent replaces unreliable manual visual estimation with a reliable automated measurement system using ultrasonic or optical signals. This substitution eliminates human error factors such as poor eyesight, fatigue, and subjectivity, providing consistent and reliable measurements through physical law-based detection methods
Solution Approach 2:
The intermediary sensor device provides reliable measurements by using physical wave propagation principles that are objective and consistent. The device acts as a neutral mediator that accurately detects liquid levels without being influenced by human factors, ensuring high reliability of inventory data through repeatable physical measurements
4Measurement precision
If automated sensor devices are used, then measurement precision and productivity improve, but device complexity and cost increase
Solution Approach 1:
The sensor device is designed with multi-functionality to justify its complexity: it performs automated measurement, wireless communication, data processing, and can interface with various container types. The device serves multiple functions including acting as a container cover, a measurement instrument, a communication device, and an inventory management node, thereby distributing its complexity across multiple useful functions
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 offers precise and automated measurement of container contents, reducing human error and labor costs by providing real-time data for inventory management and reordering, enhancing operational efficiency in commercial settings.
Implementation Method 1
a sensor device, like a container cover with a built-in content level sensor, uses ultrasonic signals to measure the liquid level in containers
Implementation Method 2
transmits an ultrasonic signal and measures the amount of time it takes for the signal to bounce off a liquid content remaining in the container and return back to the sensor
Data Source
AI summary
An identity of a container coupled to a content level sensor device is received. A plurality of signal parameters associated with the container is identified. The signal parameters are transmitted to the content level sensor device, wherein the signal parameters are indexed according to a level of content in the container.