Ultrasonic Sensor for Liquid Level Detection
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Solution Overview
Problem
Manual inventory of contents in food and beverage containers is laborious, imprecise, and error-prone, particularly challenging for commercial settings where determining the remaining amount of liquid in bottles is difficult and time-consuming.
Innovation Solution
A sensor device, such as a container cover or bottle cap, equipped with a transmitter and receiver that uses ultrasonic signals to measure the liquid level by calculating the time it takes for the signal to bounce off the liquid and return, with protective materials to prevent damage from contents and ensure accurate signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inventory methods are used to determine remaining content in containers, then device complexity is low, but measurement precision and productivity are poor
Solution Approach 1:
The patent replaces manual visual inspection (mechanical/human system) with an automated sensor device using ultrasonic signals (acoustic system). The transmitter emits ultrasonic signals that reflect off the liquid surface, and the receiver calculates the time of flight to determine liquid level, eliminating the need for manual measurement and significantly improving precision.
Solution Approach 2:
The sensor device is designed to autonomously perform inventory measurement without human intervention. The transmitter and receiver automatically emit signals, detect reflections, calculate liquid levels, and provide measurements, enabling the system to serve itself and eliminating laborious manual counting.
2Productivity
If manual inventory methods are used, then device complexity is low, but productivity is low due to laborious and time-consuming process
Solution Approach 1:
The patent replaces the mechanical process of manual visual inspection with an automated acoustic measurement system. The ultrasonic transmitter and receiver automatically measure liquid levels, providing rapid and accurate inventory data without human labor, thereby significantly improving productivity in commercial settings.
Solution Approach 2:
The sensor device enables continuous or frequent inventory measurements without interrupting operations. Unlike manual methods that require stopping work to count, the automated system can continuously monitor liquid levels, providing real-time inventory information and improving overall operational efficiency.
3Measurement precision
If manual visual inspection is used to determine liquid amount, then no additional equipment is needed, but measurement precision is poor and errors are frequent
Solution Approach 1:
The patent replaces imprecise human visual estimation with accurate acoustic measurement. The ultrasonic signals provide objective, quantifiable data about liquid levels, eliminating subjective judgment errors and achieving consistent, high-precision measurements across different users and conditions.
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary medium between the measurement system and the liquid. These acoustic waves interact with the liquid surface to provide indirect but accurate measurement of liquid level, avoiding direct contact between the sensor and liquid while maintaining measurement precision.
4Reliability
If protective materials are added to protect transmitter and receiver from liquid contents, then reliability is improved, but device complexity and signal transmission accuracy may worsen
Solution Approach 1:
The protective material acts as an intermediary layer between the sensor components and the liquid. By carefully selecting materials that are transparent to ultrasonic frequencies, the system maintains signal transmission accuracy while providing necessary protection from liquid contact and damage.
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 an accurate, efficient, and automated method to determine the remaining content in containers, reducing labor costs and improving precision in inventory management.
Implementation Method 1
A transmitter transmits an interrogation signal and a receiver receives the interrogation signal that has been reflected within a container
Implementation Method 2
measuring a time of flight of the signal from the transmitter to the receiver
Implementation Method 3
uses ultrasonic signals to measure the liquid level by calculating the time it takes for the signal to bounce off the liquid and return
Data Source
AI summary
A measurement device includes a transmitter configured to transmit an interrogation signal. The measurement device also includes a receiver configured to receive the interrogation signal that has been reflected within a container. The received reflected interrogation signal corresponds to a fill level of the container. A protective barrier covers at least the transmitter or the receiver. If the protective barrier covers the transmitter, the transmitter transmits the interrogation signal through the protective barrier and the transmitter and the protective barrier are separated by a gap.