Ultrasonic Fill Sensor Mount for Easy Replacement During Filling
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Solution Overview
Problem
Existing fill level detection systems with non-removable sensor components make it difficult to replace or service sensors during container filling.
Innovation Solution
A removable ultrasonic fill level detection system with a sensor mount comprising a cradle portion, clamping portion, and underside protective portion, allowing easy installation and removal of the ultrasonic fill level sensor, coupled with processors to determine fill levels and trigger alarms or notifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If non-removable sensor components are used in fill level detection systems, then the system structure is simplified and manufacturing cost is reduced, but sensor replacement and servicing become difficult during container filling
Solution Approach 1:
The sensor mount is divided into separate functional components: a cradle portion that mounts to the container lid, a clamping portion that secures the sensor, and an underside protective portion that shields the sensing area. This segmentation allows the sensor to be independently removed and replaced without replacing the entire mount structure, directly improving sensor replacement efficiency while maintaining manageable structural complexity through modular design
Solution Approach 2:
The clamping portion is designed to be movable between a clamped position (securing the sensor) and an unclamped position (releasing the sensor for removal). This dynamic capability enables easy sensor replacement during container filling operations. The mount structure remains relatively simple because the dynamic element is localized to the clamping mechanism rather than the entire structure
2Productivity
If removable sensor components are implemented to enable easy sensor replacement, then sensor servicing efficiency is improved, but the device structure becomes more complex
Solution Approach 1:
By segmenting the sensor mount into cradle, clamping, and protective portions, each with distinct functions, the system enables rapid sensor servicing without requiring complex overall structure. The modular segments can be independently manufactured and assembled, improving productivity while keeping individual component complexity low
Solution Approach 2:
The clamping portion is designed to allow sensor removal and installation without requiring specialized tools or complex mechanisms. The sensor can be serviced through simple manual operation of the clamping portion, achieving high servicing efficiency while minimizing the complexity of the mount structure
3Measurement precision
If the sensing portion extends through the container lid aperture, then fill level detection accuracy is improved, but the sensing portion becomes vulnerable to damage
Solution Approach 1:
The underside protective portion is positioned beneath the container lid to cushion and protect the sensing portion before damage can occur. This protective structure shields the vulnerable sensing area from impacts or contact with container contents while allowing the sensing portion to extend through the aperture for accurate fill level detection
Solution Approach 2:
The underside protective portion acts as an intermediary element between the vulnerable sensing portion and the container interior. It provides physical protection to the sensing portion while maintaining the necessary acoustic pathway for ultrasonic detection, thus preserving measurement precision while reducing damage risk
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
Facilitates efficient sensor replacement and servicing during container filling, ensuring reliable fill level detection and alerting mechanisms.
Implementation Method 1
an ultrasonic fill level sensor that includes a sensing portion
Data Source
AI summary
A fill level detection system can include an ultrasonic fill level sensor that includes a sensing portion; a sensor mount that includes a cradle portion, a clamping portion, and an underside protective portion; the clamping portion can be unmounted so that the ultrasonic fill level sensor is not retained by the clamping portion while the cradle portion is mounted on a top surface of a lid of a container; the underside protective portion can be mounted on a bottom surface of the lid of the container; the underside protective portion has a second through-cavity that is aligned with a first through-cavity of the cradle portion and an aperture in the lid of a container; and the second through-cavity at least partially receives the sensing portion of the ultrasonic fill level sensor so that the sensing portion does not extend below a bottom surface of the underside protective portion.