Ultrasonic Tank Sensor with Viscoelastic Couplant for Propane Level Detection
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Solution Overview
Problem
Current methods for accurately measuring the propane level in portable propane tanks are inaccurate, unreliable, or costly, and often fail to function effectively due to variations in temperature, pressure, tank weight inconsistencies, and limitations in ultrasonic technology usage.
Innovation Solution
A sensor arrangement comprising a housing, transducer, and couplant with a compressible viscoelastic urethane polymer or silicon rubber couplant body, which acoustically couples with the tank bottom to measure liquid height, using a magnet system for secure attachment and a low-power wireless module for data transmission to a display module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic pulse devices are used to detect propane level, then detection capability is provided, but the devices require strong coupling to the tank wall and human interaction which varies coupling quality and requires multiple measurements
Solution Approach 1:
A couplant material is introduced as an intermediary substance between the ultrasonic transducer and the tank wall to improve acoustic coupling. The couplant fills air gaps and enhances the transmission of ultrasonic waves from the transducer through the tank wall into the propane, enabling more reliable and accurate level detection with reduced need for repeated measurements.
2Reliability
If pressure-sensing devices are used to indicate low propane levels, then indication capability is provided, but pressure varies greatly with temperature and during gas flow making exact level determination difficult
Solution Approach 1:
The patent replaces pressure-based sensing with ultrasonic acoustic sensing. Instead of measuring pressure changes that are affected by temperature and flow conditions, the system uses ultrasonic wave transmission through the tank wall and propane to directly measure the physical level of propane, providing more accurate and reliable measurements independent of thermal and flow conditions.
3Measurement precision
If weight measuring devices are used to indicate gas level, then level indication is provided, but tare weights of tanks vary greatly making the device inaccurate
Solution Approach 1:
The patent replaces weight-based measurement with ultrasonic acoustic measurement. The ultrasonic transducer measures the physical height of propane by timing acoustic wave transmission, which is independent of tank weight variations. This approach works universally across different tank types and ages without requiring calibration to specific tare weights.
4Measurement precision
If visual gauges with floats are used to measure propane level, then measurement capability is provided, but the tanks are costly and cannot be used with tank exchange services
Solution Approach 1:
The system is divided into separate components: a portable sensor unit that attaches to the tank exterior and a separate display unit. This external attachment design allows the measurement system to be applied to any tank without modifying the tank itself, enabling use with tank exchange services where the sensor can be transferred to different tanks.
Solution Approach 2:
The couplant material serves as an intermediary that enables the external sensor to acoustically couple with the tank wall without requiring internal components. This external approach avoids the need for built-in gauges while achieving accurate measurement through the tank wall and propane.
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
Provides accurate, reliable, and cost-effective measurement of propane levels in portable tanks, allowing for efficient monitoring of propane levels without the need for complex installations or frequent recalibration, and is compatible with various tank sizes and types.
Implementation Method 1
a couplant body extends between the transducer and the external environment to transmit an acoustic pulse from the transducer to a tank bottom
Implementation Method 2
utilize an ultrasonic transducer to transmit an ultrasonic pulse through a couplant and a bottom of a tank
Implementation Method 3
measuring a time of flight of the ultrasonic pulse from the transducer to a liquid surface within the tank
Data Source
AI summary
A sensor arrangement for measuring liquid level in a tank can include a housing, a transducer, a couplant and a bracket for holding one or more sensor components in sensing communication with the tank. The bracket can be configured to hold both a tank and one or more sensors, which can include coupling one or both to another structure, such as a vehicle that utilizes the tank as a fuel source.