Systems and Methods for Fill Level Detection
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Solution Overview
Problem
Existing liquid dispensers face challenges in timely refilling, leading to product waste or lack of availability, due to maintenance personnel replacing reservoirs prematurely or not replacing them in a timely manner.
Innovation Solution
A fill level detection system using an accelerometer and vibration generator attached to a soap dispenser's pumphouse, which periodically or on-demand measures acceleration data to predict the product level, conserving power by alternating between active and inactive states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If maintenance personnel replace reservoirs before they are empty, then product availability is ensured, but product waste increases
Solution Approach 1:
The system performs preliminary detection of product levels and triggers refilling actions before the reservoir is completely empty. The accelerometer detects vibrations indicating low product levels, allowing maintenance personnel to refill at the optimal moment, thus ensuring availability while preventing waste from premature replacement.
Solution Approach 2:
The system implements feedback through vibration detection and wireless communication. The accelerometer continuously monitors product levels and provides feedback to maintenance personnel via alerts, enabling data-driven refilling decisions that balance availability and waste prevention.
2Loss of substance
If maintenance personnel do not replace reservoirs in a timely manner, then product waste is reduced, but product availability decreases
Solution Approach 1:
The feedback mechanism provides real-time information about product levels through wireless alerts to maintenance personnel. This enables timely refilling actions that prevent complete depletion of the reservoir, thus maintaining availability while avoiding waste from excessive early replacement.
Solution Approach 2:
The system takes preliminary action by detecting low product levels before complete depletion occurs. The vibration-based detection system triggers refilling notifications in advance, allowing maintenance personnel to act timely and maintain continuous product availability.
3Measurement precision
If the accelerometer and vibration generator remain continuously active, then fill level detection accuracy is improved, but power consumption increases
Solution Approach 1:
The accelerometer and vibration generator operate periodically rather than continuously. The system activates these components only when refilling is anticipated or detected through other means, significantly reducing power consumption while maintaining adequate measurement precision through strategic sampling of vibration data.
Solution Approach 2:
The system uses the pump's operational vibrations as a natural signal source, eliminating the need for continuous active vibration generation. The accelerometer passively detects vibrations during pump operation, providing fill level information without requiring continuous power to vibration generators.
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 system effectively determines the fill level of the container, reducing product waste and ensuring availability by alerting maintenance personnel when refilling is needed, thus enhancing patron satisfaction.
Implementation Method 1
A vibration generator that is mounted to the pumphouse. The vibration generator is operable to vibrate the pumphouse.
Implementation Method 2
An accelerometer mounted to the pumphouse. The accelerometer is configured to measure acceleration of the pumphouse.
Data Source
AI summary
A fill level detection system includes a pumphouse and a container connectable to the pumphouse. A vibration generator and an accelerometer are mounted to the pumphouse. A controller is in signal communication with the vibration generator and the accelerometer. The controller is configured for activating the vibration generator and the accelerometer, accessing acceleration data, deactivating the vibration generator and the accelerometer, and transmitting the acceleration data for analysis to compute a fill level of fluid in the container.