Vibration Fill Level Gauge for Bulk Material Containers
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Solution Overview
Problem
Existing fill level measurement technologies are often imprecise, require structural modifications to containers, and are limited to use with liquid filling goods, with sensors being prone to contamination and damage when in contact with bulk materials.
Innovation Solution
A fill level measuring device utilizing a vibration generating device, such as a percussion mechanism, in conjunction with sound and/or vibration detection and data transmission capabilities, to generate and detect vibration and sound pressure changes on a container wall, allowing for accurate determination of bulk material levels without direct contact or modification of the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed inside the container to measure fill level, then measurement capability is improved, but sensor contamination and damage from contact with bulk materials worsens reliability
Solution Approach 1:
The patent uses the container wall as an intermediary medium to transmit vibration signals from the bulk material to external sensors. Instead of placing sensors inside the container where they contact bulk material, the sensors are positioned outside and detect vibrations transmitted through the container wall, eliminating direct contact while maintaining measurement capability
Solution Approach 2:
The patent replaces direct mechanical contact sensing with indirect vibration transmission sensing. Rather than having sensors physically touch the bulk material, the system uses vibration generation and detection through the container wall structure, substituting a mechanical contact-based system with a non-contact vibration-based system
2Ease of manufacture
If structural modifications are made to containers for sensor installation, then measurement integration is improved, but manufacturing complexity and cost worsens
Solution Approach 1:
The container wall serves as an intermediary that naturally transmits vibration signals, eliminating the need for structural modifications to install sensors inside the container. The external sensors attach to the outside surface and utilize the existing container wall structure for signal transmission
Solution Approach 2:
The container wall performs multiple functions: it contains the bulk material and simultaneously serves as a transmission medium for vibration signals. This multi-functionality eliminates the need for separate sensor mounting structures or modifications, simplifying both manufacturing and installation
3Adaptability or versatility
If traditional sensors are used for bulk material measurement, then measurement coverage is improved, but adaptability to different material types worsens
Solution Approach 1:
The patent employs mechanical vibration generation and detection to measure fill levels of bulk materials. By generating vibrations in the container wall and analyzing the transmitted signals, the system achieves accurate measurements for various bulk material types without requiring material-specific sensor calibration or contact
Solution Approach 2:
The system replaces traditional contact-based sensing mechanisms with vibration-based detection through the container wall. This substitution enables the system to handle diverse bulk material types (grains, powders, pellets, etc.) with consistent accuracy, as the vibration transmission depends on the container structure rather than direct sensor-material interaction
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
Enables precise measurement of bulk material levels with less than 10% deviation, is cost-effective, and can be retrofitted to existing containers without structural changes, providing a robust and durable solution for both liquid and bulk goods.
Implementation Method 1
generate vibration and/or sound pressure changes, in particular sound waves with vibration and/or sound pressure changes, with the vibration generating device on a container wall of a container
Implementation Method 2
the sound and/or vibration detection device is designed and set up to detect these vibration and/or sound pressure changes and convert them into analog and/or digital signals
Data Source
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AI summary
The invention relates to a level gauge for determining the fill level of a container via changes in vibration and/or sound pressure triggered by a vibration generating device. The invention further relates to a kit comprising a container and at least one such level gauge. The invention also relates to a method for determining the fill level of a container with at least one level gauge via changes in vibration and/or sound pressure triggered by a vibration generating device.