Sensor device for determining a process measurement variable

Abstract

Proposed is a sensor device (100) for determining a process measurement variable of a medium (500). The sensor device has a measurement part (110) which is designed to generate a measurement signal correlating with the process measurement variable on the basis of a measurement of the process measurement variable, and sensor electronics (120) which are coupled to the measurement part (110) and are designed to generate and / or output a sensor signal on the basis of the measurement signal of the measurement part. The measurement part (110) is made at least partially of amorphous metal (130).

Description

SENSOR DEVICE FOR DETERMINING A PROCESS MEASUREMENT REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from German patent application No. 10 2024 103 141.7, filed on February 5, 2024, which is incorporated in its entirety by reference into this document. TECHNICAL FIELD

[0002] The present invention generally relates to the field of industrial process measurement technology and / or process automation. In particular, the invention relates to a sensor device for determining one or more process variables and / or process parameters, for example, a fill level of a medium, a limit level of a medium, a flow rate of a medium, a pressure of a medium, a temperature of a medium, and / or a density of a medium. The sensor device and / or a measuring part of the sensor device is at least partially made of an amorphous metal. TECHNICAL BACKGROUND

[0003] Sensor devices, also referred to as sensors or field devices, are used in almost all areas of process measurement technology and / or process automation to determine a wide variety of process parameters and / or process variables. 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, mining, and other industries. A wide 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 or sensor devices can optionally be transmitted to a control room, in which process parameters such as fill level, limit level, flow, pressure, temperature and / or density of a medium can be monitored and settings for the entire plant can be changed manually or automatically.

[0004] Sensor devices in process automation and / or process measurement technology may occasionally be exposed to aggressive and / or abrasive media. The sensor devices may also come into contact with such media, at least partially. To increase robustness, service life, and mechanical and chemical stability, sensor devices in process measurement technology are therefore often manufactured at least partially from a steel material, such as stainless steel. Despite the use of robust materials, However, sensor devices may still malfunction, particularly when used in environments or processes in which the sensor devices are subject to mechanical and / or chemical stress. SUMMARY OF REVELATION

[0005] It may therefore be desirable to provide a sensor device with increased mechanical and / or chemical robustness.

[0006] This is provided by the subject matter of the independent claim. Advantageous further developments and exemplary embodiments are specified in the dependent claims and the following description.

[0007] One aspect of the present disclosure relates to a sensor device for determining a process measurement variable of a medium, for example in process measurement technology and / or process automation. The sensor device has a measuring part which is designed and / or configured to generate a measurement signal correlating with the process measurement variable based on a measurement of the process measurement variable. Furthermore, the sensor device has sensor electronics which are coupled to the measuring part and are configured to generate and / or output a sensor signal based on the measurement signal of the measuring part, for example at an interface and / or a display of the sensor device. The measuring part is at least partially formed from amorphous metal and / or metallic glass, in particular such that the measuring part is at least partially protected against an abrasive influence of the medium.

[0008] Amorphous metals, also known as metallic glasses or non-crystalline metals, are metal alloys that exist in an amorphous state and are electrically conductive. Unlike conventional crystalline metals, in which the atoms are arranged in a regular lattice pattern, amorphous metals exhibit a disordered, glassy structure. This structure can arise, for example, from the rapid cooling of a molten metal alloy, which does not allow the atoms sufficient time to arrange themselves into an ordered crystal structure.

[0009] Due to their disordered structure, amorphous metals can exhibit greater hardness and strength than conventional metals. Furthermore, amorphous metals are characterized by improved elastic deformation. In particular, amorphous metals can deform more effectively under stress and then return to their original shape. Furthermore, the disordered structure of amorphous metals can lead to improved corrosion resistance, as there are no crystal boundaries that could be susceptible to corrosion. Furthermore, the tendency to crack formation in amorphous metals can be reduced, making them resistant to material fatigue.

[0010] Non-limiting, merely exemplary amorphous metals include zirconium-nickel-titanium-copper-beryllium alloys, iron-cobalt-silicon-boron alloys, palladium alloys, and magnesium-zinc-calcium alloys. However, the present disclosure is not limited to these amorphous metals.

[0011] Overall, amorphous metals therefore have better chemical and mechanical wear properties than conventional metals. The design of the measuring part of the sensor device, at least partially, from amorphous metal can therefore improve mechanical stability, Improve the robustness, corrosion resistance, and service life of the sensor device. In particular, the sensor device can be better protected against environmental and media influences. This can also enable the use of the sensor device in extremely aggressive and / or abrasive media.

[0012] In the context of the present disclosure, the sensor device may refer to a field device and / or a sensor configured to determine, ascertain, and / or detect one or more process parameters and / or process variables, for example, of a process in process automation and / or process measurement technology. Here and below, determining, measuring, and / or ascertaining a process parameter and / or a process variable may be understood as determining, measuring, and / or ascertaining a value of a process parameter and / or a value of a process variable. Such values ​​of process parameters and / or process variables may also be referred to as measured values ​​below.

[0013] The measurement signal and / or the sensor signal can thus correlate with a value of the process variable and / or be indicative of the value of the process variable. For example, the sensor electronics can be configured to determine and / or ascertain a value of the process variable based on the measurement signal from the measuring part.

[0014] The sensor device and / or the measuring part can be designed for non-contact or contact measurement. In a non-contact measurement, the process variable, or a corresponding value, is measured without contact and / or contact of the measuring part with the medium. In a contact measurement, however, the process variable is measured with at least part of the measuring part in contact with the medium.

[0015] The measuring part of the sensor device can, for example, refer to a sensor head of the sensor device, which can be aligned in the direction of the medium and / or can be at least partially in contact with the medium.

[0016] In the context of the present disclosure, the medium can be any desired medium, for example a liquid, fluid, at least partially gaseous, pasty, granular medium, or a combination thereof. The medium can also be a vaporous medium and / or a foam, thus a fluid that can be largely mixed with air. In particular, the medium can be a fluid, a liquid, or a bulk material. In the case of a bulk material, strong abrasive forces can sometimes act on the sensor device, which the sensor device can withstand due to the use of the amorphous metal. Liquids or gases, on the other hand, can sometimes contain aggressive chemicals that can attack the material of the sensor device. The sensor device according to the invention can also withstand such stresses well due to the use of the amorphous metal for at least part of the measuring part.

[0017] The medium can be arranged, for example, in a container, tank, container, pit, silo, and / or storage facility. Likewise, the sensor device and / or at least part of the measuring element can also be arranged in the container, tank, container, pit, silo, and / or storage facility. Alternatively, the medium can also be stored in a storage facility, for example, a bulk material dump.

[0018] According to one embodiment, the measuring part is designed to be at least partially in contact with the medium for determining the process measurement variable. In other words The measuring part and / or the sensor device can be designed for contact measurement. Especially during contact measurements, the sensor device can be exposed to increased mechanical and / or chemical stresses. Constructing the measuring part at least partially from amorphous metal can therefore advantageously increase the service life of the sensor device, particularly during contact measurements.

[0019] According to one embodiment, the measuring part is configured to be arranged at a distance from a surface of the medium for determining the measurement signal. In other words, the measuring part and / or the sensor device can be designed for non-contact measurement. Even with non-contact measurements, the sensor device can be exposed to mechanical and / or chemical stresses, for example, due to contamination or adhesion of the medium and / or aggressive gases or vapors. Constructing the measuring part at least partially from amorphous metal can therefore advantageously ensure an increased service life of the sensor device, even with non-contact measurement.

[0020] According to one embodiment, the measuring part is at least partially coated with the amorphous metal on the outside of a side of the measuring part facing the medium and / or on a region of the measuring part that contacts the medium. In particular, the coating can follow a shape, geometry, and / or contour of the measuring part. A coating can protect the measuring part comprehensively, effectively, and cost-efficiently. Furthermore, a coating can also be applied to existing sensor devices.

[0021] A coating made of amorphous metal can be used, in particular, for metallic parts and / or components of the measuring element. This allows the measuring element to be better protected from environmental and media influences. The coating can be thin and / or geometrically follow the sensor geometry. Such an amorphous coating can be applied to any type of sensor or sensor device in various measurement physics. Due to the continued electrical conductivity, it is also possible to guide radar waves, for example. This allows it to be used in various physical measurement principles, particularly the physical measurement principle of guided radar, and thus for various types of sensor devices.

[0022] For example, a coating layer thickness can range from a few micrometers to several hundred micrometers. Thicker layers in the range of one or several millimeters are also possible.

[0023] According to one embodiment, the measuring part is fully coated with amorphous metal on an outer side and / or a side of the measuring part facing the medium. For example, all areas of the measuring part exposed to the medium can be coated with amorphous metal. This allows the measuring part to be comprehensively protected against the influences of the medium.

[0024] For example, a thin, full-surface coating can be applied over the measuring part, so that medium contact can only occur with the coating and no longer with the measuring part or sensor device itself. The coating can be applied completely over the geometry of the measuring part. This allows even undercuts or notches to be coated.

[0025] The coating consists at least partially of an amorphous metal with significantly improved wear and corrosion properties compared to conventional metals. Furthermore, the material is harder and stronger than commercially available steel materials. Amorphous metals or metallic glasses can combine these improved mechanical properties with simultaneously retained electrical conductivity. The coatings can therefore be used in several physical measurement principles, e.g., rods in guided radar, tuning forks in vibronic sensors, floats in magnetic valve gauges on bypasses, and others, as further described below.

[0026] According to one embodiment, the measuring part is formed from solid amorphous metal, at least in a partial area. In other words, one or more components of the measuring part can be made from solid amorphous metal.

[0027] According to one embodiment, the sensor device further comprises a process connection for attaching the sensor device to a container, and a sealing region for sealing the process connection. The sealing region is at least partially formed from amorphous metal and / or at least partially coated with amorphous metal. A coating and / or formation made of amorphous metal can thus be drawn over the media-contacting region of the sealing surface and / or the sealing region. As a result, only amorphous metal can come into contact with the medium to be measured, and the process connection and other components of the sensor device can be effectively protected against media influences.

[0028] According to one embodiment, the sensor device is configured as a guided radar sensor device for determining a fill level, a limit level, and / or a humidity of the medium. Alternatively or additionally, the measuring part is designed as a measuring probe that comes into contact with the medium. At least part of the measuring probe can be coated with amorphous metal or made of amorphous metal.

[0029] According to one embodiment, the sensor device is configured as a free-radiating radar sensor device for determining a fill level of the medium. Alternatively or additionally, the measuring part is designed as a radar antenna for emitting a radar signal and / or for receiving a radar signal reflected from a surface of the medium. At least part of the radar antenna can be coated with amorphous metal or made of amorphous metal.

[0030] According to one embodiment, the sensor device is configured as a vibronic limit level sensor for determining a limit level of the medium. Alternatively or additionally, the measuring part is designed as a vibrating element in contact with the medium. At least part of the vibrating element can be coated with amorphous metal or made of amorphous metal.

[0031] According to one embodiment, the sensor device is configured as a pressure measuring device for determining the pressure of the medium. Alternatively or additionally, the measuring part is designed as a pressure measuring cell in contact with the medium. At least part of the pressure measuring cell, for example, a membrane and / or a base body of the pressure measuring cell, can be coated with amorphous metal or made of amorphous metal.

[0032] According to one embodiment, the sensor device is designed as a bypass level gauge, an interface detector, a flow velocity gauge, a density gauge, and / or a temperature sensor. The service life of such sensor devices can also be increased by using amorphous metal.

[0033] For example, the sensor device can be designed as a bypass level measuring device. The measuring part can be a float with a magnet guided in a bypass pipe. The bypass pipe can be in fluid communication with a container, so that a fill level in the bypass pipe can correspond to the fill level in the container. A magnetic flap indicator can optionally be arranged on the bypass pipe so that a position of the float can be visually displayed on the bypass pipe. The float of the measuring part can be coated with amorphous metal or made of amorphous metal. Optionally, the bypass pipe and / or a connection between the bypass pipe and the container can also be coated with amorphous metal or made of amorphous metal.

[0034] A further aspect of the present disclosure relates to the use of a sensor device which is at least partially formed from amorphous metal for determining a process measurement variable of a medium in process measurement technology.

[0035] Any description described above and below with respect to one aspect of the present disclosure applies equally to all other aspects of the present disclosure.

[0036] In the following, embodiments of the invention are described with reference to the figures. SHORT DESCRIPTION OF THE CHARACTERS

[0037] Fig. 1 shows a sensor device according to an embodiment.

[0038] Fig. 2 shows a container with sensor devices according to embodiments.

[0039] Fig. 3 shows a sensor device according to an embodiment.

[0040] Fig. 4 shows a sensor device according to an embodiment.

[0041] Fig. 5 shows a sensor device according to an embodiment.

[0042] Fig. 6 shows a sensor device according to an embodiment.

[0043] Similar, similarly acting, identical, or identically functioning elements are provided with similar or identical reference numerals in the figures. The figures are merely schematic and not to scale. DETAILED DESCRIPTION OF EMBODIMENTS

[0044] Figure 1 shows a sensor device 100 for determining a process variable of a medium 510 (see Figure 2) according to one exemplary embodiment. The process variable can be, for example, a fill level, a density, a humidity level, a temperature, a pressure, a flow rate, or another process parameter characterizing the medium.

[0045] The sensor device 100 has a measuring part 110 which is designed to generate a measurement signal correlating with the process measurement variable based on a measurement of the process measurement variable or a corresponding value.

[0046] Furthermore, the sensor device 100 has a sensor electronics 120. For example, the sensor electronics 120 can have an electronic circuit 122 and / or a control unit 122, which can be accommodated in a housing 123 and operatively connected to the measuring part is coupled. The sensor electronics 120 are configured to generate and / or output a sensor signal based on the measurement signal of the measuring part. The sensor electronics can also be configured to determine one or more values ​​of one or more process measurement variables based on the measurement signal and / or output them as one or more sensor signals.

[0047] For example, the sensor device 100 can have an interface 126 for outputting the sensor signal, for example, to a control room or a data processing device. Further optionally, the sensor device 100 can have a display 124 on which the value of the process measurement variable can be displayed.

[0048] At least a portion 130 of the measuring part 110 is made of amorphous metal and / or metallic glass. In particular, the measuring part 110 may have a coating 130 made of amorphous metal. Alternatively or additionally, a portion 130 of the measuring part 110 may also be made of solid amorphous metal.

[0049] Furthermore, the sensor device 100 has a process connection 112 for attaching the sensor device 100 to a container 500 (see Figure 2), and a sealing region 114 for sealing the process connection 112. The process connection 112 can, for example, have a thread for screwing the sensor device 100 into a container wall and / or a flange. The sealing region 114 can, for example, designate a sealing surface. Optionally, at least a portion of the sealing region 114 can be coated with amorphous metal, so that medium contact can only occur for coating purposes. Alternatively, a portion of the process connection 112 can also be made solid from amorphous metal.

[0050] The sensor device 100 shown schematically in Figure 1 can be designed for contactless or contact measurement, as described below in Figure 2.

[0051] Figure 2 shows a container 500 with sensor devices 100a, 100b according to exemplary embodiments. A medium 510 is accommodated in the container 500. Unless otherwise described, the sensor devices 100a, 100b have the same components and elements as the sensor device 100 of Figure 1.

[0052] In the example shown in Figure 2, the sensor device 100a is arranged in a ceiling of the container 500 above the medium 510 and is designed for non-contact measurement. The measuring part 110a is arranged inside the container 500, and the sensor electronics 120a is arranged, for example, outside the container 500. The measuring part 110a is arranged at a distance from a surface of the medium 500. For example, the sensor device 100a can be a free-radiating radar for determining a fill level of the medium 510.

[0053] The sensor device 100b, on the other hand, is arranged in a side wall of the container 500 and is designed for contact measurement. The measuring part 110b is arranged inside the container 500, and the sensor electronics 120b is arranged, for example, outside the container 500. The measuring part 110b can be in contact with the medium 510. The sensor device 100b can be configured, for example, as a guided radar sensor device for determining a fill level, a limit level and / or a humidity of the medium. The sensor device 100b can also be configured as a vibronic limit level sensor for determining a limit level of the medium 510. The sensor device 100b can also be configured as a pressure measuring device for determining a Pressure of the medium 510 can be designed as a bypass level measuring device, as an interface detector, as a flow velocity measuring device, as a density measuring device and / or as a temperature sensor.

[0054] Figures 3 to 6 each show a sensor device 100 according to exemplary embodiments. Unless otherwise described, the sensor devices 100 of Figures 3 to 6 have the same elements and features as the sensor devices 100, 100a, 100b described in the preceding Figures 1 and 2.

[0055] In the example of Figure 3, the sensor device 100 is configured as a vibronic limit level sensor 100 for determining a limit level of the medium 500, wherein the measuring part 110 is designed as a medium-contacting vibrating element 110. The vibrating element 110 can, for example, be a fork, a tuning fork, and / or a vibrating rod.

[0056] The sensor device 100 has a flange 112 as a process connection 112 and a sealing surface 114 or a sealing area 114. The flange 112 is connected to the measuring part 110 via one or more tubular intermediate pieces 115.

[0057] In the embodiment shown in Figure 3, the sealing surface 114, the at least one intermediate piece 115 and the measuring part 110 are coated with a coating 130 made of amorphous metal, so that all media-contacting parts of the sensor device 100 are comprehensively protected.

[0058] In the example of Figure 4, the sensor device 100 is configured as a guided radar sensor device 100 for determining a fill level, a limit level and / or a humidity of the medium 510, wherein the measuring part 110 is configured as a measuring probe 110 in contact with the medium.

[0059] The sensor device 100 has a screw thread 112 as process connection 112 and a sealing surface 114 or a sealing area 114. The process connection 112 is connected to the measuring part 110.

[0060] In the embodiment shown in Figure 4, the sealing surface 114 and the measuring part 110 are covered with a coating 130 made of amorphous metal, so that all media-contacting parts of the sensor device 100 are comprehensively protected.

[0061] In the example of Figure 5, the sensor device 100 is configured as a free-radiating radar sensor device 100 for determining a fill level of the medium 510, wherein the measuring part 110 is configured as a radar antenna 110 for emitting a radar signal and / or for receiving a radar signal reflected on a surface of the medium 510.

[0062] The sensor device 100 has a screw thread 112 as process connection 112 and a sealing surface 114 or a sealing area 114. The process connection 112 is connected to the measuring part 110.

[0063] In the embodiment shown in Figure 5, the sealing surface 114 and the measuring part 110 are coated with a coating 130 made of amorphous metal, so that all media-contacting parts of the sensor device 100 are comprehensively protected.

[0064] In the example of Figure 6, the sensor device 100 is designed as a bypass level measuring device 100. The measuring part 110 can denote a float 110 with a magnet 115 guided in a bypass pipe (not shown). The bypass pipe can be in fluid communication with a container 500, so that a fill level in the bypass pipe can correspond to the fill level in the container 500. A magnetic flap indicator can optionally be arranged on the bypass pipe, so that a position of the float 110 can be visually displayed on the bypass pipe. The float 110 can be coated with amorphous metal 130 or made of amorphous metal. In particular, the float 110 can be provided with a coating 130 made of amorphous metal over its entire surface.

[0065] Additionally, it should be noted that the terms "comprising" and "having" do not exclude other elements, and the indefinite articles "a" or "an" do not exclude a plurality. Furthermore, it should be noted that features described with reference to one of the above embodiments can also be used in combination with other features of other embodiments described above. Reference signs in the claims are not to be considered as limitations.

Claims

CLAIMS 1. A sensor device (100) for determining a process measurement variable of a medium (500), comprising: a measuring part (110) configured to generate a measurement signal correlating with the process measurement variable based on a measurement of the process measurement variable; and sensor electronics (120) coupled to the measuring part (110) and configured to generate and / or output a sensor signal based on the measurement signal of the measuring part; wherein the measuring part (110) is formed at least partially from amorphous metal (130).

2. Sensor device (100) according to claim 1, wherein the measuring part (110) is designed to be at least partially in contact with the medium for determining the process measurement variable.

3. Sensor device (100) according to claim 1, wherein the measuring part (110) is arranged at a distance from a surface of the medium in order to determine the measuring signal.

4. Sensor device (100) according to one of the preceding claims, wherein the measuring part (110) is at least partially coated with the amorphous metal (130) on the outside, on a side of the measuring part facing the medium (500) and / or on a region of the measuring part contacting a medium.

5. Sensor device (100) according to one of the preceding claims, wherein the measuring part (110) is coated over its entire surface with amorphous metal (130) on an outer side and / or a side of the measuring part facing the medium.

6. Sensor device (100) according to one of the preceding claims, wherein the measuring part (110) is formed from amorphous metal (130) at least in a partial area.

7. Sensor device (100) according to one of the preceding claims, further comprising: a process connection (112) for attaching the sensor device (100) to a container; and a sealing region (114) for sealing the process connection; and wherein the sealing region is at least partially formed from amorphous metal and / or at least partially coated with amorphous metal (130).

8. Sensor device (100) according to one of the preceding claims, wherein the sensor device (100) is configured as a guided radar sensor device for determining a fill level, a limit level, and / or a humidity of the medium; and / or wherein the measuring part (110) is configured as a measuring probe in contact with the medium.

9. Sensor device (100) according to one of the preceding claims, wherein the sensor device is configured as a free-radiating radar sensor device for determining a fill level of the medium; and / or wherein the measuring part (110) is configured as a radar antenna for emitting a radar signal and / or for receiving a radar signal reflected from a surface of the medium.

10. Sensor device (100) according to one of the preceding claims, wherein the sensor device is configured as a vibronic limit level sensor for determining a limit level of the medium; and / or wherein the measuring part (110) is designed as an oscillating element in contact with the medium.

11. Sensor device (100) according to one of the preceding claims, wherein the sensor device is configured as a pressure measuring device for determining a pressure of the medium; and / or wherein the measuring part (110) is designed as a pressure measuring cell in contact with the medium.

12. Sensor device (100) according to one of the preceding claims, wherein the sensor device is designed as a bypass level measuring device, as an interface detector, as a flow velocity measuring device, as a density measuring device and / or as a temperature sensor.

13. Use of a sensor device (100) which is at least partially made of amorphous metal for determining a process measurement variable of a medium in process measurement technology.

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