Analytical device for determining a parameter of a medium, sensor adapter and method for producing same

Abstract

The invention relates to a sensor adapter (39) for providing electrical, optical, electro-optical and / or pneumatic connection elements (52) which can be connected to components (81) of a measuring assembly (80) accommodated in a housing (20), and by means of which the measuring assembly (80) can be coupled to a process environment (5). The connection elements (52) are integrated in connection modules (51) which are fixed in position in a fixing element (45) in the interior (43) of the sensor adapter (39). The connection modules (51) are advantageously part of a modular system (50) of standardized components.

Description

[0001] Analysis device for determining a characteristic of a medium, sensor adapter and method for its production

[0002] The invention relates to an optical analysis device for determining a characteristic of a medium. Furthermore, the invention relates to a sensor adapter for optically, electrically, and / or pneumatically coupling the analysis device to a process environment, as well as a manufacturing method for such a sensor adapter.

[0003] In many areas of the manufacturing and processing industries, optical measurement methods are used to evaluate the condition or quality of a product or intermediate product. The term "optical measurement method" is used below to refer to a measurement method using electromagnetic radiation, particularly electromagnetic radiation in the spectral range between infrared and ultraviolet. "Optical measurement" therefore includes, in particular, measurements in the far infrared (FIR), mid-infrared (MIR), near-infrared (NIR), visible spectral range, and UV range.

[0004] In the chemical and pharmaceutical industries and in food production, optical, particularly spectroscopic, analysis systems are used. These systems are used to carry out in-process measurements of a measured variable of a measuring fluid that can be detected using optical means in a production environment using a probe. For example, an immersion probe can be used that is immersed in the measuring fluid contained in a reaction vessel or a pipe. A measuring beam emitted by a radiation source is guided through the measuring fluid by the immersion probe over a measuring section and then directed to a detector, in which the intensity, spectrum, etc. of the measuring radiation influenced by the measuring fluid are analyzed. The results provide information about the state variables (e.g. concentration, density, etc.) of the measuring medium.

[0005] A measuring system suitable for such measurements comprises a radiation source, a detector, and a controller, all arranged together in a housing. If the optical analysis system is to be used in a process environment, the housing surrounding the measuring system must be robustly designed to protect it from temperature influences, dirt, dust, vibrations, etc. A measuring system with such a housing is known from DE 10 2012 019 433 A1. A sensor device and a spatially separate electronic device are arranged inside the housing.

[0006] International patent application WO 2022 / 223425 A1 also discloses an optical analysis device that can be connected to a process environment using a sensor adapter. The sensor adapter comprises a tube, into the interior of which electromagnetic radiation from the radiation source can be radiated onto the measuring medium in the process environment, and the measuring radiation from the measuring medium can be redirected to the sensor device.

[0007] The object of the present invention is to further develop the coupling of the measuring arrangement to a process environment known from WO 2022 / 223425 A1 in such a way that not only electromagnetic radiation but also electrical signals, media (e.g., compressed air, inert gas), etc., can be exchanged between the measuring devices. For this purpose, a sensor adapter is to be provided that allows a wide range of different measuring situations and with the help of which the measuring arrangement is pressure- and gas-tightly shielded from the process environment.

[0008] This object is achieved by a sensor adapter having the features of claim 1, a method for producing the sensor adapter having the features of independent claim 9, and an analysis device having the features of claim 11. The subclaims relate to advantageous developments and variants of the invention.

[0009] Such a sensor adapter for connecting a plurality of sensors and / or actuators of different types located in a process environment to a measuring arrangement accommodated in a housing must, depending on the application, provide electrical, optical, electro-optical and / or pneumatic connecting elements (e.g. plugs, sleeves, sockets, etc.) on its side facing the process environment, to which the associated connecting lines (wires, cables, optical fibers, hoses, etc.) can be attached in the process environment. According to the invention, these connecting elements are integrated into connection modules which, during the manufacture of the sensor adapter, are inserted into a fixing element and fixed in position there. This fixing element is then arranged in the interior of the sensor adapter, aligned there in a desired position and fixed in this position by at least partially filling the interior of the sensor adapter.The position alignment can be carried out using an assembly aid placed on the end of the sensor adapter.

[0010] The fixing element can accommodate multiple connection modules. It bundles the connection modules and thus represents an auxiliary device for positioning and fixing the connection modules in the interior of the sensor adapter. The fixing element is a universal element that can be used for any application. The connection modules accommodated in the fixing element, however, are individually adapted to the respective measuring situation. Advantageously, the connection modules are part of a modular system of standardized components, so that for a specific application, the required connection modules are taken from the kit, inserted into the fixing element, and integrated together into the interior of the sensor adapter. To provide such a modular system, the individual connection modules preferably all have the same width, corresponding to the width of a receiving area in the fixing element.Thus, a standardized fixing element can accommodate a variety of different combinations of connection modules.

[0011] In particular, the sensor adapter according to the invention enables the simple coupling or decoupling of sensors and / or measuring heads.

[0012] For the mechanical connection of the sensor adapter to a housing of the measuring system, the sensor adapter is advantageously provided with a connection plate with which it can be screwed to the housing. Furthermore, the sensor adapter advantageously has a flange for the mechanical connection of the sensor adapter to a process environment. To thermally shield the measuring system from the process environment, the sensor adapter can be provided with a cooling device. This cooling device expediently comprises a cooling line through which a coolant can flow, which surrounds an outer wall of the sensor adapter in a ring.

[0013] In the following, embodiments and variants of the invention are explained in more detail with reference to the drawings.

[0014] Figure 1 is a perspective external view of an optical analysis device according to the invention with a sensor adapter;

[0015] Figure 2 is a schematic partial sectional view of the analysis device of Figure 1;

[0016] Figure 3a is a sectional view of a sensor adapter for a spectroscopic application;

[0017] Figure 3b is a sectional view of a sensor adapter for an application with optical fibers and electrical cables;

[0018] Figure 4a is a plan view of a fixing frame to be mounted in the interior of the sensor adapter;

[0019] Figure 4b is a plan view of different connecting modules that can be accommodated in the fixing frame of Figure 4a;

[0020] Figure 4c is a perspective view of a fixing element with a fixing frame and three connecting modules accommodated therein;

[0021] Figure 5a - 5d Individual steps in the production of the sensor adapter:

[0022] Figure 5a: Fixing element with connection modules and connected cables;

[0023] Figure 5b: Sensor adapter with inserted fixing element;

[0024] Figure 5c: Sensor adapter with attached mounting aid; Figure 5d: Sensor adapter after pouring the potting compound;

[0025] Figure 6 a perspective view of the sensor adapter with attached mounting aid

[0026] Figure 1 shows a perspective external view and Figure 2 a partial sectional view of an analysis device 10 for determining at least one characteristic of a measuring medium using an optical, electronic, electro-optical and / or electromechanical method. In the present case, the analysis device 10 comprises a housing 20 in which a measuring arrangement 80 with a plurality of components 81 is accommodated. The measuring arrangement 80 shown here comprises in particular a radiation source (not shown in the partial sectional view of Figure 2), a detector 83 (in the present case a spectrometer 83') and a controller 84 and can also contain further optical, electronic, electro-optical and / or electromechanical components 81. The controller 84 serves, among other things, to coordinate the timing between the spectrometer 83' and the radiation source and can also perform further control and evaluation functions, e.g.the calculation of a spectrum or a process parameter from the signals of the spectrometer 83' and the forwarding of measurement results, for example via Ethernet or a process interface, to an external space 4 located outside the housing 20.

[0027] The housing 20 is designed in two parts and comprises an upper shell 22 and a lower shell 23, which are connected to one another by means of a detachable connection, for example a screw connection. The lower shell 23 is provided with a base plate 24 at the bottom, in the area of ​​which a cooling device for controlling the temperature of the measuring arrangement 80 can be arranged. The lower shell 23 has a connecting area 25 to which a sensor adapter 39 (described in more detail below) is attached. With the help of this sensor adapter 39, the measuring arrangement 80 in the interior 21 of the housing 20 can be mechanically, electrically and optically connected to a process environment 5 and a media and data exchange can take place between the analysis device 10 and a measuring medium located in a process environment. The housing 20 also has through-holes 75 for media, power orSignal cables which serve for the media and energy supply as well as for the external data exchange of the optical, electrical, electro-optical and electromechanical components 81 arranged in the housing 20.

[0028] In the assembled position shown in Figure 1, the two housing shells 22, 23 enclose a closed cavity 21 in which a measuring arrangement 80 can be completely accommodated. A circumferential seal 29, for example an O-ring or a flat gasket made of plastic or metal, can be arranged between the upper shell 22 and the lower shell 23, by means of which the interior 21 of the housing 20 can be hermetically sealed. This is particularly advantageous if the analysis device 10 is to be used in a contaminated or potentially explosive process environment.

[0029] Located in the interior 21 of the housing 20 is a component carrier 38, to which the components 81 of the measuring arrangement 80 are mounted. The component carrier 38 is detachably attached, for example, via a screw connection, to the lower shell 23 of the housing 20. Such a detachable connection of the component carrier 38 to the lower shell 23 makes it possible to replace the currently used component carrier 38 with another component carrier (of the same or different design); furthermore, differently equipped component carriers 38 can be used, so that one and the same housing 20 can be used to accommodate different measuring arrangements 80.

[0030] In the present embodiment, the sensor adapter 39 arranged in the connection area 25 serves to conduct excitation pulses (e.g., excitation radiation) into the process environment and to introduce measurement pulses (e.g., radiation reflected by the measuring medium) into the housing interior 21. Sectional views of the sensor adapter 39 for two different applications are shown in Figures 3a and 3b. The sensor adapter 39 comprises a tubular adapter housing 40, the end 40' of which facing the measuring arrangement 80 is provided with a connection plate 42 to be fastened to the housing 20 of the measuring arrangement 80. The end 40" facing away from the housing 20 is provided with an annular, circumferential end flange 55.By means of this end flange 55, the sensor adapter 39 can be fastened to a counterpart (not shown in Figures 3a, 3b) in the process environment 5, for example to a container carrying the measuring medium 6, using a clamp connection, in particular a Tri-Clamp connection.

[0031] For a given measuring task with the required measuring arrangement 80 and the associated cables 37, a dedicated sensor adapter 39 must be provided which integrates the cables, hoses, etc. required for the measuring task and ensures process-reliable decoupling between the process environment 5 and the housing interior 21. In the simplest case, the sensor adapter 39 is used for a measuring task in which only electromagnetic radiation is introduced or discharged from the housing interior 21 into the process environment, i.e. in which there is no need to route cables or media lines through the sensor adapter into the process environment 5. In this case, a mechanical seal, for example a window 41 transparent to the radiation used, can be attached to the end 40" of the sensor adapter 39 facing away from the measuring arrangement 80, which prevents the penetration of dust or contamination into the interior 21 of the housing 20.Depending on the spectral range used, a window 41 made of glass, quartz, sapphire, etc. can be used.

[0032] More complex applications require - in addition to or instead of the input and output of electromagnetic radiation - additional sensors, for example temperature measurements, flow measurements, etc. For this purpose, lines 37 (electrical lines, optical fibers, pneumatic lines, etc.) must be integrated into an interior space 43 of the adapter housing 40, by means of which the components 81 (e.g. spectrometers, radiation sources, microprocessors, ...) of the measuring arrangement 80 can interact with the process environment 5 and / or the measuring medium 6 located there (see Figure 3b). Thus, electrical lines 37a can be arranged in the interior space 43 of the adapter housing 40, for example lines for connecting sensors that record process variables or environmental information (temperature, flow rate, leakage, ...) of the measuring medium 6 and / or the process environment 5.If measurements are to be further performed on the measuring medium 6 using electromagnetic radiation, the sensor adapter 39 additionally serves to accommodate optical fibers 37b for introducing and discharging optical radiation into the process environment 5. If pneumatic actuators are to be operated in the process environment 5, the associated compressed air lines are also routed in the interior 43 of the sensor adapter 39. Furthermore, control lines can also be provided to exchange control signals between the controller 84 in the housing interior 21 and actuators in the outer area 4 of the housing 20, e.g., to control an automated measurement of the white level.

[0033] All lines 37 routed through the sensor adapter 39 (optical fibers, pneumatic lines, data or control lines, etc.) must be provided with suitable (optical, electrical, pneumatic, etc.) connecting elements 52 in an exit area 44 of the sensor adapter 39 facing the process environment 5 in order to enable simple and rapid separation of the lines 37 routed in the interior 43 of the sensor adapter 39 when the optical analysis device 10 is removed from the process environment 5.

[0034] An advantage of the solution according to the invention is that the two-part housing 10 does not have to be opened in order to adapt the analysis device 10 to a wide variety of measuring tasks.

[0035] In order to guide a variety of different lines 37 through the interior 43 of the sensor adapter 39 and to position the connecting elements 52 associated with these lines 37 precisely, a fixing element 45 is arranged in the interior 43 of the adapter housing 40 at the end facing the process environment 5, the outer contour of which is adapted to the inner contour 43 of the adapter housing 40 and, in the present exemplary embodiment, has a cylindrical shape, see the perspective illustration in Figure 4c. The fixing element 45 comprises a fixing frame 46 with a U-shaped base module 46' and a terminal module 46", between which a cavity 47 with a width of 57 is formed (see Figure 4a). This cavity 47 serves to accommodate connecting modules 51, which are inserted into the base module 46' and which are held in position with the aid of the terminal module 46".For mounting sensor adapters 39 for a wide variety of applications, a modular system 50 consisting of various standardized connection modules 51 is provided, from which the components required for a given measuring task can be selected and assembled. The connection modules 51 of this modular system 50 differ in their functionalities and are each equipped with specific connecting elements 52 (electrical connectors, fiber optic couplings, etc.) that enable a standardized connection to an external cable. The width 56 of the connection modules 51 is standardized (and corresponds to the width of the cavity 47 in the fixing frame 46), but their heights can vary depending on the functionality.Some of them are shown as examples in Figure 4b: Connection module 51a comprises six pin contacts 52a for securing / connecting six electrical cables, connection module 51b comprises two sockets 52b for securing / connecting two fiber optic cables, and connection module 51c comprises two grommets 52c for securing / connecting a pneumatic hose. To fill any gaps that may occur in the fixing frame 46, the modular system 50 further comprises spacers 52d of various heights. The connection modules 52 are provided laterally with projections 53, which, when assembled with the fixing frame 46, engage in grooves 54 in the base module 46' of the fixing frame.

[0036] In the embodiment shown in Figure 4c, the fixing frame 46 contains two connection modules 51b for connecting two optical fibers each, and one connection module 51a for connecting electrical cables. The optical fibers are used for coupling / decoupling electromagnetic radiation in two different spectral ranges. The electrical cables are used, for example, for temperature measurements, flow measurements, etc.

[0037] To produce a sensor adapter 39 with the desired connecting elements 52, the fixing frame 36 must be precisely positioned within the sensor adapter 39, and the interior 43 of the sensor adapter 39 must then be sealed gas- and pressure-tight. This is done in the following process steps:

[0038] - First, connecting modules 51 matching the desired connecting elements 52 are selected, provided on one side with the associated cables 37 on the housing side, and arranged in the fixing frame 46. The ends of the cables 37 facing away from the fixing frame 46 are provided with sleeves 63 for later connection of the cables 37 to the components 81 of the measuring arrangement 80 (step A, see Figure 5a). Optical fibers must be mounted in such a way that the end face spacing is matched to the wavelength range, since otherwise white light interference may occur. The fixing element 45 produced in this way is inserted into the interior 43 of the sensor adapter 39 and secured there with a spring washer 48 shown in Figure 3b (step B, see Figure 5b).

[0039] - The fixing element 45 is then aligned, oriented, and positioned in the desired position using a mounting aid 60 (Figure 5c). The mounting aid 60 is in the form of a ring that is placed on the end flange 55 of the sensor adapter 39 and is provided with a recess 59 that engages a projection 58 on the fixing frame 46 (see the perspective view in Figure 6). By rotating the mounting aid 60, the fixing element 45 can be rotated into the desired position in the interior 43 of the sensor adapter 39 and fixed in this orientation by means of a clamp 61.

[0040] - Subsequently, the interior 43 of the sensor adapter 39 is at least partially filled with a potting compound 62 (step C, see Figure 5d). After the potting compound 62 has hardened, the fixing element 45, together with the connection modules 51 contained therein, is fixed in the adapter housing 40, and any gaps that may exist between the inner wall of the adapter housing 40 and the outer wall of the fixing element 45 are sealed. As a result, when the sensor adapter 39 is assembled with the housing 20 of the measuring arrangement 80, the housing interior 21 is sealed pressure- and gas-tight from the process environment 5. - The assembly aid 60 can now be removed.

[0041] - Once the potting compound 62 has cured, the remaining interior space 43 of the adapter housing 40 is filled with additional potting compound (see Figure 3b); the filling level may not exceed the height of the sleeves 63, so that the sleeves 63 protrude from the potting compound after it has cured. - Finally, the sensor adapter 39 is checked for leaks using a helium leak detector, and the lines 37 are checked for functionality.

[0042] In this way, sensor adapters 39 for a wide variety of applications can be manufactured using the modular system 50 of connection modules 51. As described above, the sensor adapter 39 represents an (optical, electrical, etc.) interface between the measuring arrangement 80 in the interior 21 of the housing 20 and the harsh process environment 5. Additionally, the sensor adapter 39 has the task of thermally shielding the temperature-sensitive components 81 in the interior 21 of the housing 20 from the process environment 5, in which high temperatures and / or strong temperature fluctuations can occur.

[0043] Such thermal decoupling of the sensor adapter 39 can be achieved, for example, by a ceramic plate integrated into the adapter housing 40 (and advantageously arranged in the region of the end 40" facing away from the measuring arrangement 80) as a thermal insulator. Alternatively or additionally, the sensor adapter 39 can be provided with a cooling device 90, which effects thermal decoupling between the process environment 5 and the housing interior 21 and protects the components 81 in the housing interior 21 from significant thermal stress. For this purpose, an outer region 92 of the adapter housing 40 can be provided with a cooling line 91, for example a copper tube, which surrounds the outer region 92 of the adapter housing 40 in a ring shape and through which a cooling liquid circulates; such a cooling line 91 is shown in dashed lines in Figure 3b. The cooling line 91 of the sensor adapter 39 can be connected to a cooling device of the housing 20 of the measuring arrangement 80.Advantageously, the associated cooling coil is arranged directly below the component carrier 38, so that an air gap exists between the cooling coil and the base plate 24 of the housing 20. Such an air gap ensures good thermal insulation of the measuring arrangement 80 from the base plate 24 and ensures good and efficient thermal regulation of the component carrier 38. List of reference symbols.

[0044] 4 Outdoor area, outdoor space

[0045] 5 Process environment

[0046] 6 Measuring medium

[0047] 10 Analysis device

[0048] 20 housings

[0049] 21 Interior of the housing

[0050] 22 upper shell

[0051] 23 Lower shell

[0052] 24 Base plate

[0053] 25 Connection area

[0054] 29 Seal

[0055] 37 Cable (optical, electrical, ...)

[0056] 38 component carriers

[0057] 39 sensor adapters

[0058] 40 adapter housing with ends 40', 40"

[0059] 41 windows

[0060] 42 connection plate

[0061] 43 Interior sensor adapter

[0062] 44 Exit area from the sensor adapter

[0063] 45 Fixing element

[0064] 46 fixing frame 46' basic module 46" end module

[0065] 47 Cavity fixing frame

[0066] 48 spring ring

[0067] 50 modular system

[0068] 51 Connection module of the modular system

[0069] 52 (optical, electrical, ...) connecting element

[0070] 53 projections on the connecting elements

[0071] 54 Groove in the base module of the fixing frame end flange

[0072] Width connection module

[0073] Width of the cavity in the fixing frame

[0074] Projection fixing frame

[0075] Recess in assembly aid

[0076] Assembly aid

[0077] bracket

[0078] Potting compound

[0079] sleeve

[0080] Through holes

[0081] Measuring arrangement

[0082] Components in the housing 20

[0083] Detector 83' Spectrometer

[0084] Controller

[0085] Cooling device

[0086] Cooling line

[0087] Exterior wall sensor adapter

Claims

Patent claims 1. Sensor adapter (39) for connecting a plurality of sensors and / or actuators of different types located in a process environment (5) to a measuring arrangement (80) accommodated in a housing (20), and for providing a plurality of electrical, optical, electro-optical and / or pneumatic connecting elements (52) which can be connected to components (81) of the measuring arrangement (80) and by means of which the measuring arrangement (80) can be coupled to the plurality of sensors and / or actuators in the process environment (5), characterized in that the connecting elements (52) are integrated into connecting modules (51) which are positionally fixed in a fixing element (45) in the interior (43) of the sensor adapter (39).

2. Sensor adapter (39) according to claim 1, characterized in that the fixing element (45) comprises a fixing frame (46) for receiving one or more connection modules (51).

3. Sensor adapter (39) according to claim 2, characterized in that the connection modules (51) accommodated in the fixing frame (46) are part of a modular system (50) of standardized components.

4. Sensor adapter (39) according to claim 2 or 3, characterized in that the connecting modules (51) have a standardized width (56), and that the fixing frame (46) has a cavity (47) whose width (57) is adapted to the width (56) of the connecting modules (51).

5. Sensor adapter (39) according to one of the preceding claims, characterized in that the sensor adapter (39) comprises a connection plate (42) for mechanically connecting the sensor adapter (39) to a housing (20) of the measuring arrangement (80).

6. Sensor adapter (39) according to one of the preceding claims, characterized in that the sensor adapter (39) comprises a closing flange (55) for mechanically connecting the sensor adapter (39) to a process environment (5).

7. Sensor adapter (39) according to one of the preceding claims, characterized in that the sensor adapter (39) comprises a cooling device (90).

8. Sensor adapter (39) according to claim 6, characterized in that the cooling device (90) comprises a cooling line (91) through which a coolant can flow and which surrounds an outer wall (92) of the sensor adapter (39) in an annular manner.

9. A method for producing a sensor adapter (39) according to one of claims 1 to 7, comprising the steps: - selecting and fixing the selected connection modules (51) in the fixing frame (46) of the fixing element (45) (step A); - positioning the fixing element (45) in an interior space (43) of the sensor adapter (39) (step B); - filling at least some sections of the interior (43) of the sensor adapter (39) with a casting compound (step C).

10. The method according to claim 9, characterized in that in the course of positioning the fixing element (45) (step B) with the aid of an assembly aid (60) a positional alignment of the fixing element (45) in the interior space (43) of the sensor adapter (39) takes place.

11. Analysis device (10) for determining at least one characteristic of a medium, with a measuring arrangement (80) with several components (81, 82, 83, 84) which are arranged in an interior space (21) of a housing (20), - wherein the housing (20) has at least one inlet / outlet area (40) of electrical, optical, electro-optical and / or pneumatic lines, - and wherein the analysis device (10) has a sensor adapter (39) according to one of claims 1 to 6, which can be detachably fastened to the housing (20) in the inlet / outlet region.

12. Analysis device (10) according to claim 11, characterized in that the housing (20) of the analysis device (10) comprises a cooling device which can be coupled to a cooling device (91) of the sensor adapter (39).

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