Sensor, mount and sensor system

Abstract

The invention relates to a sensor having a sensor housing (110), a first fastening element (104) which defines a centre of rotation of the sensor (100), and a first annular fastening device (107) which has a ferromagnetic material, the first fastening element (104) being located on the rotational axis of the first annular fastening device. The sensor is configured to be pivotably fastened to a closed wall of a plastic container.

Description

[0001] Sensor, bracket and sensor system

[0002] Reference to related applications

[0003] This application claims priority from German patent application No. 10 2023 134 620.2, filed on December 11, 2023, which is incorporated in its entirety by reference into this document.

[0004] Technical area

[0005] The present invention relates to process automation in industrial or private environments. In particular, the present invention relates to a sensor for process automation in industrial or private environments, a sensor mount, and a sensor system.

[0006] background

[0007] In process automation in industrial or private environments, sensors are used to measure, for example, fill levels, limit levels or pressure.

[0008] Such sensors are typically screwed to the container, for example via a flange connection or a screw thread on the sensor housing.

[0009] WO 2021 / 197613 A1 describes a sensor with a magnetic fastening means designed to attach the sensor to a closed wall of a plastic container. Summary

[0010] It is an object of the present invention to provide an alternative fastening of sensors to a container.

[0011] This object is achieved by the features of the independent patent claims. Further developments of the invention emerge from the subclaims and the following description of embodiments.

[0012] A first aspect of the present disclosure relates to a sensor for process automation in industrial or domestic environments, which is configured for attachment to the inside of a closed wall of a plastic container and for detecting a measured variable of a medium in the plastic container. The sensor comprises a sensor housing, a first fastening element, and a first annular fastening device. The first fastening element defines a center of rotation or pivot of the sensor, about which the sensor can rotate when attached to the container. The first fastening element is designed for pivotally attaching the sensor to the closed wall of the plastic container.

[0013] The first annular fastening device is arranged (concentrically) around the first fastening element. In other words, the first fastening element is located on the rotation axis or axis of symmetry of the first annular fastening device. The first annular fastening device comprises a ferromagnetic material or consists of such a material.

[0014] This allows for a flexible and adjustable sensor mount, whereby the sensor can be attached to the container and tilted using magnetic forces.

[0015] According to a further embodiment of the present disclosure, the first annular fastening device is designed in the form of an annular band.

[0016] For example, the first annular fastening device and / or the first fastening element is integrated into the sensor housing or attached to the inner wall of the sensor housing. According to a further embodiment of the present disclosure, the first annular fastening device is designed in the form of a plurality of fastening elements arranged spaced apart from one another along a circle.

[0017] According to a further embodiment of the present disclosure, the sensor housing is convex, curved outwards, in the region of the first fastening element and the first annular fastening device.

[0018] According to a further embodiment of the present disclosure, the sensor housing has a plurality of surface segments in the region of the first fastening element and the annular fastening device, which are arranged at an angle to one another. A fastening element can be located in or under each of these surface segments.

[0019] According to a further embodiment of the present disclosure, the first fastening element is designed to be pivotable.

[0020] According to a further embodiment of the present disclosure, the first fastening element comprises or consists of a ferromagnetic material.

[0021] According to a further embodiment of the present disclosure, the sensor comprises a control unit and a wireless communication interface configured to communicate with a sensor mount for the sensor.

[0022] According to a further embodiment of the present disclosure, the control unit is configured to detect, by evaluating the measurement data acquired by the sensor, that a bulk material cone is forming that distorts the level measurement, and, in response, to determine a new measurement point so that error-free measurement is again possible. These measurement points can, for example, be defined in advance and taught to the sensor during a learning and calibration process.

[0023] Another aspect of the present disclosure relates to a sensor holder configured for attachment to the exterior of a closed wall of a plastic container and for holding a sensor described above and below. The sensor holder comprises a second fastening element configured for attaching the sensor to the closed wall of the plastic container, as well as a second annular fastening device, on whose rotational axis or mirror axis the second fastening element is located. The second annular fastening device comprises an electromagnet arrangement.

[0024] According to a further embodiment of the present disclosure, the sensor mount comprises a control unit and a wireless communication interface configured to communicate with the wireless communication interface of the sensor.

[0025] According to a further embodiment of the present disclosure, the control unit of the sensor holder is configured to control the electromagnet arrangement in such a way as to pivot the sensor by magnetic force.

[0026] According to a further embodiment of the present disclosure, the control unit is configured to detect, by evaluating the measurement data acquired by the sensor, that a bulk material cone is forming that distorts the level measurement, and, in response, to determine a new measurement point so that error-free measurement is again possible. These measurement points can, for example, be defined in advance and taught to the sensor during a learning and calibration process.

[0027] Another aspect of the present disclosure relates to a sensor system comprising a sensor described above and below and a sensor mount described above and below.

[0028] The sensor system is designed, for example, such that the first annular fastening device of the sensor corresponds to the second annular fastening device of the sensor holder. Likewise, the first fastening element of the sensor corresponds to the second fastening element of the sensor holder.

[0029] The term "process automation in industrial environments" can be understood as a branch of technology that includes measures for operating machines and systems without human intervention. One goal of process automation is to automate the interaction of individual components of a plant in the chemical, food, pharmaceutical, petroleum, paper, cement, shipping, or mining industries. A variety of sensors can be used for this purpose, which are specifically adapted to the specific requirements of the process industry, such as mechanical stability, insensitivity to contamination, extreme temperatures, and extreme pressures. Measured values ​​from these sensors are usually transmitted to a control room, where process parameters such as fill level, limit level, flow rate, pressure, or density are monitored, and settings for the entire plant can be changed manually or automatically.

[0030] A sub-area of ​​process automation in the industrial environment concerns the logistics automation of plants and the logistics automation of supply chains. With the help of distance and angle sensors, processes inside or outside a building, or within a single logistics facility, are automated in the field of logistics automation. Typical applications for logistics automation systems include baggage and freight handling at airports, traffic monitoring (toll systems), retail, parcel distribution, and building security (access control). What the aforementioned examples have in common is that the respective application requires presence detection in combination with precise measurement of the size and location of an object.For this purpose, sensors based on optical measuring methods using lasers, LEDs, 2D cameras or 3D cameras that measure distances according to the time of flight (ToF) principle can be used.

[0031] Another sub-area of ​​process automation in the industrial environment concerns factory-to-production automation. Applications for this can be found in a wide variety of industries, such as automotive manufacturing, food production, the pharmaceutical industry, and packaging in general. The goal of factory automation is to automate the production of goods using machines, production lines, and / or robots, i.e., to run it without human intervention. The sensors used here and the specific requirements regarding measurement accuracy in detecting the position and size of an object are comparable to those in the previous example of logistics automation. The terms used in the claims should be construed to give them the broadest possible reasonable interpretation in accordance with the above description.For example, the use of the article "a" or "the" when introducing an element should not be interpreted as excluding a plurality of elements. Similarly, the mention of "or" should be interpreted as including a plurality of elements, so that the mention of "A or B" does not exclude "A and B" unless it is clear from the context or preceding description that only one of A and B is meant. Further, the phrase "at least one of A, B, and C" should be understood as one or more elements from a group of elements consisting of A, B, and C, and should not be interpreted as requiring at least one of each of the listed elements A, B, and C, regardless of whether A, B, and C are related as categories or otherwise.Furthermore, the mention of "A, B and / or C" or "at least one of A, B or C" should be interpreted to include any single entity of the listed elements, e.g., A, any subset of the listed elements, e.g., A and B, or the entire list of elements A, B and C.

[0032] Further embodiments of the present disclosure are described below with reference to the figures. Where the same reference numerals are used in the figures, they denote identical or similar elements. The representations in the figures are schematic and not to scale.

[0033] Short description of the characters

[0034] Fig. 1 shows a container with a sensor system attached to it.

[0035] Fig. 2 shows a sensor holder.

[0036] Fig. 3 shows a container with a sensor system attached to it in a tilted state.

[0037] Fig. 4 shows a cross-sectional view of a sensor. Fig. 5 shows a cross-sectional view of a sensor according to another embodiment.

[0038] Detailed description of embodiments

[0039] Fig. 1 shows a container 105 to which a sensor system is attached. The sensor system consists of a sensor 100, which is attached to the container wall inside the container, and a sensor mount 200, which is located on the opposite side of the container wall.

[0040] The sensor mount 200 has a (second) fastening element 204 located in the center of the underside of the sensor mount 200 and, for example, integrated into the housing wall of the sensor mount 200 or attached internally thereto. This second fastening element 204 is, for example, a permanent magnet or a ferromagnetic material.

[0041] Around the second fastening element 204 there is a ring of electromagnets 203, which is also referred to above as the second annular fastening device.

[0042] The individual electromagnets are connected to the electronics or control unit 202 of the sensor mount 200 and can be individually controlled by it. The control unit 202 is connected to the wireless communication interface 209, which receives control data from a corresponding communication interface 109 of the sensor 100.

[0043] The sensor 100 has a sensor housing 102 in which, in addition to the wireless communication interface 109, a control unit 108 is located, which controls the measurements of the sensor 100 and generates control data for the controller 202 of the sensor holder 200, which is then transmitted from the communication interface 109 to the communication interface 209 of the sensor holder 200.

[0044] The housing 102 of the sensor 100 has a convex shape in the upper region. Located on the central axis of the sensor 100 in the upper region, either embedded in the sensor housing or attached internally, is a "first" fastening element 104, for example in the form of an electromagnet, a permanent magnet, or a ferroelectric.

[0045] Also located on top of or in the housing is a first annular fastening device 107, concentric with the axis described above, on which the first fastening element 104 is located.

[0046] The positions and dimensions of the first fastening element 104 and the first annular fastening device 107 correspond to the positions and dimensions of the corresponding counterparts of the sensor holder 200, namely the second fastening element 204 and the second annular fastening device 203.

[0047] The sensor 100 is held to the sensor holder 200 by magnetic forces acting through the container wall.

[0048] This enables the self-contained sensor 100 to be mounted in the container 105 using magnets 203, 204, 107, 104. The sensor 100, for example, does not have a display or operating module. The sensor mount 200 has magnets and is designed to allow multiple positioning / orientations of the sensor 100. The sensor mount 200 and the sensor 100 can communicate with each other via the wireless interfaces 209, 109, for example, using short-range communication (NFC, LoRa, etc.).

[0049] A control unit 202 integrated in the sensor holder 200 controls the electromagnets of the second annular fastening device 203.

[0050] The sensor 100 can have a convex upper surface, which also contains magnets or a ferromagnetic metal. The electronics in the sensor holder 200 can then influence the orientation of the sensor 100 by switching certain magnets on and off. The magnets in the sensor holder 200 can be switched individually.

[0051] The convex surface of the sensor 100 causes it to tilt around its center of rotation. Located at the center of rotation is a tiltable / pivotable mount (first mounting element 104) for attaching the sensor 100 to the container 105. This mount may be, for example, a magnet 104. The magnetic counterpart 204 for this can then be located in the sensor holder 200.

[0052] The sensor 100 can be communicatively connected to the sensor mount 200 via the wireless communication interface 109, so that control commands can be transmitted to the control unit 202 of the sensor mount 200. The control unit 202 in the sensor mount 200 can then convert these commands into switching on or off the electromagnets of the second annular fastening device 203, thus moving the sensor 100 into different orientations / positions.

[0053] This means that the sensor 100 can position itself in specific orientations using the sensor mount 200. These orientations can be different measuring points, for example, on a bulk material dump.

[0054] The sensor electronics can be so intelligent that they automatically detect when, for example, a bulk material cone forms that distorts the actual container measurement level. In response, the control unit 108 determines a new measurement point, allowing error-free measurement again. These measurement points can, for example, be defined in advance and taught to the sensor during a learning and calibration process.

[0055] The sensor 100 can, for example, detect that the container is being filled very quickly within a certain time and then move to a different measuring point accordingly by tilting itself.

[0056] The sensor described above can therefore independently move to predefined measuring points, detect the formation of repose cones, and react to them by controlling the magnetic sensor holder 200 accordingly in order to be tilted. The container wall is usually located between the sensor 100 and the sensor holder 200. However, it can also be provided that the sensor holder 200 is also attached to the inside of the container so that the sensor holder 200 and the sensor 100 touch each other. Communication between the sensor 100 and the sensor holder 200 can be wireless using NFC, LoRa, etc. The surface of the sensor 100 that touches the container wall can be convex, which simplifies tilting of the sensor. In particular, the (autonomous) sensor 100 can independently move to predefined measuring points using the sensor holder 200 and align itself spatially accordingly.

[0057] Fig. 2 shows a sensor mount 200. The second fastening element 204 is arranged in the center of the sensor mount 200. Surrounding it is the second annular fastening device 203, which in this embodiment consists of individual electromagnets. Each of these electromagnets is connected to the control unit 202 and can be individually controlled by it.

[0058] The electromagnets are arranged in a ring on the sensor holder 200. The sensor and the sensor holder 200 form a magnetic connection through the container wall. The magnet 204 is preferably very strong so that the sensor can be securely fastened. The ring-shaped electromagnets of the ring-shaped fastening device 203 can be individually switched on and off. The sensor 100 has a curve on its upper side, where its magnets are located (see Fig. 1). The magnetic connection between the magnets 104, 204 is so strong that it holds the sensor 100 in place in any application. In addition, individual ring segments of the ring-shaped fastening device 203 of the sensor holder can now be switched on. These then pull the sensor 100 towards themselves or towards the container wall in this area. The curvature of the surface of the sensor 100 causes it to tilt. This is shown in Fig. 3.

[0059] Fig. 4 shows another possible embodiment of the housing 102 of the sensor 100. In this embodiment, the top side of the housing 102 consists of several segments arranged at an angle to one another, i.e., with different surface orientations. A ferromagnetic element of the annular fastening 107 is located in or on each of these segments. The first fastening element 104 is located centrally in the topmost segment.

[0060] Another embodiment is shown in Fig. 5, which has more segments than the embodiment in Fig. 4. Here, too, a ferromagnetic element of the annular fastening device 107 is located in each of the segments. More precisely, in this embodiment, two annular fastening devices 107 are provided, which are arranged concentrically to one another and thus form two rings with different diameters. This enables a two-stage tilting of the sensor 100, depending on which ring is currently attracted by the corresponding electromagnet of the sensor holder.

[0061] In this case, the sensor holder 200 also has two annular fastening devices whose diameter and position correspond to the annular fastening devices of the sensor 100.

Claims

Patent claims 1. A sensor (100) for process automation in an industrial or private environment, for detecting a measured variable of a medium in a plastic container (105), comprising: a sensor housing (102); a first fastening element (104) defining a center of rotation of the sensor (100) and designed for pivotally attaching the sensor (100) to the closed wall of the plastic container (105); a first annular fastening device (107), on whose axis of rotation the first fastening element (104) is located; wherein the first annular fastening device (107) comprises a ferromagnetic material.

2. Sensor (100) according to claim 1, wherein the first annular fastening device (107) is designed in the form of an annular band.

3. Sensor (100) according to claim 1, wherein the first annular fastening device (107) is designed in the form of a plurality of fastening elements which are arranged spaced apart from one another along a circle.

4. Sensor (100) according to one of the preceding claims, wherein the sensor housing (102) is convex in the region of the first fastening element (104) and the first annular fastening device (107).

5. Sensor (100) according to one of claims 1 to 3, wherein the sensor housing (102) in the region of the first fastening element (104) and the annular fastening device (107) has a plurality of surface segments which are arranged at an angle to one another.

6. Sensor (100) according to one of the preceding claims, wherein the first fastening element (104) is designed to be pivotable.

7. Sensor (100) according to one of the preceding claims, wherein the first fastening element (104) comprises a ferromagnetic material.

8. Sensor (100) according to one of the preceding claims, further comprising: a control unit (108) and a wireless communication interface (109) configured to communicate with a sensor holder (200) for the sensor (100).

9. Sensor (100) according to one of the preceding claims, arranged for attachment to the inside of a closed wall of a plastic container (105).

10. A sensor holder (200) configured for attachment to the outside of a closed wall of a plastic container (105) and for holding a sensor (100) according to any one of the preceding claims, comprising: a second fastening element (204) configured for attaching the sensor (100) to the closed wall of the plastic container (105); a second annular fastening device (203), on the rotational axis of which the second fastening element (204) is located; wherein the second annular fastening device (203) comprises an electromagnet arrangement.

11. Sensor mount (200) according to claim 10, further comprising: a control unit (202) and a wireless communication interface (209) configured to communicate with the wireless communication interface (109) of the sensor (100).

12. Sensor holder (200) according to claim 11, wherein the control unit (202) is configured to control the electromagnet arrangement in such a way as to pivot the sensor (100) by magnetic force.

13. Sensor system comprising a sensor (100) according to one of claims 1 to 9 and a sensor holder (200) according to one of claims 10 to 12.

14. Sensor system according to claim 13, wherein the first annular fastening device (107) corresponds to the second annular fastening device (203); and wherein the first fastening element (104) corresponds to the second Fastening element (204) corresponds.

15. Sensor system according to claim 13 or 14, wherein the control unit (202) of the sensor holder (200) and / or the control unit (108) of the sensor (100) is configured to detect, by evaluating the measurement data acquired by the sensor (100), that a bulk material cone is forming which distorts the level measurement, and to determine a new measuring point in response thereto so that an error-free measurement is again possible.

Images