Limit-level sensor with amorphous metal

Abstract

The invention describes a limit-level sensor (100) which is intended for determining a limit level of a medium (510) and has a sensor head (110), which is designed to generate an electric field, and sensor electronics (120), which are coupled to the sensor head (110) and are designed to detect on the basis of a determination of a change in the electric field and / or a capacitance of the sensor head when the limit level of the medium (510) is reached and / or the medium comes into contact with at least part of the sensor head. At least part of the sensor head (110) is made of amorphous metal.

Description

LIMIT LEVEL SENSOR WITH AMORPHOUS METAL REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from the German patent application No. 10 2024 103 139.5, filed on February 5, 2024, which is incorporated herein by reference in its entirety. 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 point level sensor for determining the limit level of a medium, for example, in a vessel, pipe, container, tank, or the like. The point level sensor is made at least partially of an amorphous metal. TECHNICAL BACKGROUND

[0003] Various sensors or field devices, such as point level sensors, pressure measuring cells, or level measuring devices, are used in almost all areas of process measurement technology and / or process automation to determine a 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 variety of sensors can be used for this purpose, which are particularly adapted to the specific requirements of the process industry, such as mechanical stability, insensitivity to contamination, extreme temperatures and extreme pressures.

[0004] A distinction is regularly made between contactless and contact measurements in sensors or field devices. In a contactless measurement, a measurement of a A process variable or process parameter is measured without contact and / or contact between the sensor and the medium. In a contact measurement, however, the process variable is measured with at least part of the sensor in contact with the medium.

[0005] In particular, sensors for contact measurements, especially point level sensors, are at least partially in direct contact with the medium to be measured and are therefore directly exposed to the mechanical and / or chemical stresses of the medium. Depending on the process, the medium can be chemically aggressive and / or abrasive, which can increase wear on point level sensors and reduce their service life. To increase robustness, service life, and mechanical and chemical stability, point level sensors are therefore often manufactured at least partially from a steel material. Despite Even when using robust materials, malfunctions can still occur, especially when used in environments or processes in which the sensors or point level sensors are subject to mechanical and / or chemical stress. SUMMARY OF REVELATION

[0006] It may therefore be desirable to provide a point level sensor with increased mechanical and / or chemical robustness, and therefore, for example, increased service life.

[0007] 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.

[0008] One aspect of the present disclosure relates to a point level sensor for determining a limit level of a medium, for example in a vessel, pipe, container, silo, tank, stockpile, or the like. The point level sensor has a sensor head configured to generate an electric field. Furthermore, the point level sensor has sensor electronics coupled to the sensor head and configured to determine, based on a determination of a capacitance of the sensor head and / or based on the determination of a change in the electric field, when the limit level of the medium has been reached and / or when the medium has touched at least part of the sensor head. At least part of the sensor head is made of amorphous metal.

[0009] 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.

[0010] 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.

[0011] 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.

[0012] Overall, amorphous metals therefore have better chemical and mechanical wear properties than conventional metals. The construction of at least part of the point level sensor from amorphous metal can therefore improve mechanical stability, robustness, Improve the corrosion resistance and service life of the point level sensor. In particular, the use of amorphous metal provides better protection against environmental and media influences than conventional metals. This can also allow the point level sensor to be used in extremely aggressive and / or abrasive media.

[0013] 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 point level sensor, which the point level sensor 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 point level sensor. The point level sensor according to the invention can also withstand such stresses well due to the use of the amorphous metal.

[0014] The medium can be arranged, for example, in a vessel, tank, pipe, line, hose, receptacle, container, pit, silo, stockpile, and / or storage facility. Likewise, the point level sensor can also be arranged at least partially in the vessel, tank, pipe, line, hose, receptacle, container, pit, silo, stockpile, and / or storage facility.

[0015] In the context of the present disclosure, the point level sensor can refer to a sensor or field device in process measurement technology and / or process automation that can detect and / or determine the reaching of a limit level and / or predefined level of the medium based on the detection of a change in the electric field of the sensor head. The point level sensor can, for example, be arranged at a position on or in a container that corresponds to the limit level. As soon as the sensor head comes into contact with the medium, the sensor electronics can detect this and, for example, issue a corresponding switching command, for example at an interface of the point level sensor and / or on a display. Point level sensors are therefore often also referred to as point level switches.

[0016] For example, the sensor electronics can be configured to generate and / or output a switching signal when the medium comes into contact with at least a part of the sensor head, wherein the switching signal is indicative of the reaching of the limit level of the medium.

[0017] When the sensor head comes into contact with the medium, the capacitance of the sensor head, such as the capacitance of an electrode of the sensor head, can change. The sensor electronics can therefore be configured to detect a change in the capacitance of the sensor head, a change in the capacitance of one or more electrodes of the sensor head, and / or a change in the capacitive component of the electric field, and to detect the reaching of the limit level based thereon. The limit level sensor of the present disclosure can therefore also be referred to as an impedance limit level switch.

[0018] According to one embodiment, the sensor head is at least partially coated on the outside with the amorphous metal. In particular, the coating can follow a shape, geometry and / or contour of that of the sensor head. With a coating, the sensor head can be protected comprehensively, effectively and cost-efficiently. For example, the point level sensor can thus be subjected to increased They can withstand process pressures and / or determine them more precisely. Furthermore, a coating can also be applied to existing point level sensors.

[0019] According to one embodiment, the sensor head is formed, at least in a partial area, from solid amorphous metal. This allows the sensor to particularly benefit from the increased hardness and improved deformation properties of amorphous metal compared to conventional metals. For example, the point level sensor can thus withstand increased process pressures and / or determine them more precisely.

[0020] According to one embodiment, the sensor head has at least one electrode, wherein at least a portion of the at least one electrode is made of amorphous metal. This ensures the electrical conductivity required for the function as an electrode and increases the mechanical and / or chemical resilience of the point level sensor.

[0021] According to one embodiment, the at least one electrode of the sensor head is designed as a ring electrode. However, other electrode types and geometries are also possible.

[0022] According to one embodiment, the at least one electrode comprises at least two concentrically arranged, electrically conductive electrode elements, which are made at least partially, in particular entirely, of amorphous metal. For example, the at least two concentrically arranged electrode elements can be separated and / or spaced apart from one another by electrically insulating material. Such a construction can enable precise limit level determination with a compact design.

[0023] According to one embodiment, the electrically insulating material contains ceramic. In particular, a combination of ceramic for insulating areas and amorphous metal for the at least one electrode can increase the resilience of the point level sensor against mechanical and / or chemical influences of the medium.

[0024] According to one embodiment, the sensor head is configured to generate an alternating electric field. The sensor electronics can be configured, for example, to determine whether the limit level has been reached based on a change in the capacitive and / or resistive component of the electric field, for example, the alternating field.

[0025] According to one embodiment, the sensor electronics are configured to determine a capacitive and a resistive component of the electric field, or a change in the capacitive and resistive component, in order to distinguish between adhesion of medium to the sensor head and at least partial coverage of the sensor head with the medium. The resistive component of the electric field is often also referred to as the conductive component. In particular, by determining the resistive or conductive component, the sensor electronics can determine whether contact with the medium is an adhesion or an actual coverage of the sensor head with medium. This can ensure reliable determination of the limit level.

[0026] According to one embodiment, the sensor electronics are configured to detect coverage of at least part of the sensor head based on a conduction measurement and / or conductivity measurement. Such a conduction measurement and / or conductivity measurement can be performed based on the determination of the resistive component and / or a change in the resistive component of the electric field.

[0027] According to one embodiment, the point level sensor further comprises a process connection for attaching the point level sensor to a container, and a sealing region for sealing the process connection, wherein 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 the coating or the amorphous metal can have contact with the medium to be measured, and the process connection and other components of the point level sensor and / or sensor head can be effectively protected against media influences.

[0028] The advantages of the present disclosure and exemplary embodiments are summarized below. The excellent corrosion and abrasion properties of metallic glasses or amorphous metals can increase the service life of the point level sensor and ensure functional reliability and precise point level detection. Amorphous metals can be used, in particular, to coat part of the sensor head or to form metallic components, such as electrodes (elements), of the sensor head.

[0029] Conventional point level sensors typically use steel materials, such as stainless steel, for the electrodes and a plastic, such as PEEK (polyetheretherketone), for the electrically insulating areas between the electrode elements. Both materials, stainless steel and PEEK plastic, tend to be considered soft and are therefore susceptible to long-term exposure to abrasive media. This exposure can occur, for example, with pasty liquids during the filling or emptying of containers. Flows inside containers caused by mixing tools can also occur.

[0030] The point level sensor according to the invention, in which at least part of the sensor head is made of amorphous material, can be characterized by reduced wear. For example, stainless steel components can be replaced with amorphous metal. Optionally, the plastic can also be replaced with ceramic, which can further increase the load capacity of the point level sensor and also ensure electrical insulation. The significantly increased hardness and better resistance to abrasion enable longer service life of the point level sensor. Overall, the point level sensor can thus also be exposed to higher process pressures.

[0031] A further aspect of the present disclosure relates to the use of a limit level sensor, which is formed at least partially from amorphous metal, for determining a limit level of a medium.

[0032] 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.

[0033] In the following, embodiments of the invention are described with reference to the figures. SHORT DESCRIPTION OF THE CHARACTERS

[0034] Fig. 1 shows a limit level sensor according to an embodiment.

[0035] Fig. 2 shows a cross section of the limit level sensor of Figure 1 according to an embodiment.

[0036] Fig. 3 shows limit level sensors according to embodiments.

[0037] 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 THE INVENTION

[0038] Figure 1 shows a point level sensor 100 according to one embodiment. Figure 2 shows a cross-section through the point level sensor 100 of Figure 1. Figure 3 shows the use of point level sensors 100 according to Figures 1 and 2 for determining a limit level of a medium 510 in a container 500 and / or a pipeline 505.

[0039] Figure 3 shows, by way of example, a point level sensor 100 for determining the point level in the pipeline 505 and another point level sensor 100 for measuring the point level in the container 500. The point level sensors 100 of Figures 1 to 3 can be designed identically, so that the following description applies equally to Figures 1 to 3.

[0040] The point level sensor 100 has a sensor head 110 and a sensor electronics 120 communicatively and / or electrically coupled to the sensor head 110.

[0041] The sensor head 110 has one or more ring electrodes 112, wherein an outer side of the at least one ring electrode 112 can define a region of the limit level sensor 100 which can come into contact with the medium 510.

[0042] In the example of Figures 1 and 2, the at least one ring electrode 112 has three concentrically arranged electrode elements 114, 115, 116. Electrode element 116 forms the outermost electrode element and defines the outer surface 113 of the sensor head 110. Electrode element 115 is arranged between the electrode elements 114 and 116, and electrode element 114 forms the inner electrode element.

[0043] Each of the electrode elements 114, 115, 116 is electrically insulated from the other electrode elements 114, 115, 116. In particular, the electrode elements 114 and 115 are arranged concentrically to one another and electrically separated and / or insulated from one another by one or more electrically insulating elements 117. Similarly, the electrode elements 115 and 116 are electrically separated and / or insulated from one another by electrically insulating elements 118. The electrically insulating elements 117 and 118 can ensure a spacing of the electrode elements 114 and 115, or the electrode elements 115 and 116, respectively. As a result, different electrical potentials can be generated between the electrode elements 114 and 115 and between 115 and 116.

[0044] The sensor electronics 120 are configured to control the sensor head 110 and / or the electrode 112 and to generate an electric field, in particular an alternating electric field, at the tip of the sensor head 110. In particular, electric fields can be generated between adjacent electrode elements 114, 115, 116.

[0045] When the medium 510 touches the sensor head 110, the capacitance of the sensor head 110, the at least one electrode 112, and / or the electric fields between the electrode elements 114, 115, 116 change. The sensor electronics 120 can detect such a change in the capacitance or the electric fields, for example, by determining the capacitive component of one or more electric fields between adjacent electrode elements 114, 115, 116. Based on such a detection of the capacitance and / or a change in the capacitance, the limit level sensor 100 or the sensor electronics 120 can detect that the limit level has been reached.

[0046] Optionally, the sensor electronics 120 can also determine a resistive or conductive component of one or more electric fields between adjacent electrode elements 114, 115, 116 in order to detect adhesion of medium 510 to the sensor head 110 based on a conduction or conductivity measurement, or to distinguish between adhesion and coverage with medium 510.

[0047] To increase the service life and robustness of the point level sensor 100, the electrode elements 114, 115, and 116 are made of amorphous metal. Alternatively, both or one component can be coated with amorphous metal.

[0048] Optionally, the electrically insulating elements 117, 118 can be made of ceramic. This can result in a completely enclosed surface for the process medium 510 to be measured, with improved wear properties.

[0049] The combination of the electrical conductivity of the amorphous metal and the electrical insulation properties of the ceramic ensures that the point level sensor 100 continues to function. Under high pressure, plastics, which are often used in point level sensors, tend to flow. By using ceramic, higher pressures can be used in the process due to the lower tendency to flow. The point level sensor 100 can therefore withstand higher pressures of the medium 510.

[0050] Further optionally, a process connection 130 of the point level sensor 100, such as a flange or a screw thread, for attaching the point level sensor 100 to a container 500, 505 can also be made at least partially of amorphous metal. For example, a sealing area 132 of the process connection can be made of amorphous metal or coated with amorphous metal. This can further reduce the wear tendency of the point level sensor.

[0051] 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 may also be used in combination with other features of other embodiments described above. Reference signs in the claims are not to be considered limitations.

Claims

CLAIMS 1. A limit level sensor (100) for determining a limit level of a medium (510), the limit level sensor (100) comprising: a sensor head (110) configured to generate an electric field; and sensor electronics (120) coupled to the sensor head (110) and configured to determine, based on a determination of a change in the electric field and / or a capacitance of the sensor head, when the limit level of the medium (510) has been reached and / or when the medium has made contact with at least a portion of the sensor head; wherein at least a portion of the sensor head (110) is made of amorphous metal.

2. Limit level sensor (100) according to claim 1, wherein the sensor head (110) is at least partially coated on the outside with the amorphous metal.

3. Limit level sensor (100) according to one of the preceding claims, wherein the sensor head (110) is formed from amorphous metal at least in a partial area.

4. The level sensor (100) according to any one of the preceding claims, wherein the sensor head (110) has at least one electrode (112); and wherein at least a portion of the at least one electrode is made of amorphous metal.

5. Limit level sensor (100) according to claim 4, wherein the at least one electrode (112) of the sensor head is designed as a ring electrode.

6. Limit level sensor (100) according to one of claims 4 and 5, wherein the at least one electrode (112) has at least two concentrically arranged, electrically conductive electrode elements (114, 115, 116) which are made at least partially, in particular completely, of amorphous metal.

7. Limit level sensor (100) according to claim 6, wherein the at least two concentrically arranged electrode elements (114, 115, 116) are separated and / or spaced from one another by electrically insulating material (117, 118).

8. The level sensor (100) according to claim 7, wherein the electrically insulating material (117, 118) contains ceramic.

9. Limit level sensor (100) according to one of the preceding claims, wherein the sensor head (110) is configured to generate an alternating electric field.

10. Limit level sensor (100) according to one of the preceding claims, wherein the sensor electronics (120) are configured to generate and / or output a switching signal upon contact of the medium (510) with at least a part of the sensor head, wherein the switching signal is indicative of the reaching of the limit level of the medium (510).

11. Limit level sensor (100) according to one of the preceding claims, wherein the sensor electronics (120) are configured to determine a capacitive and a resistive component of the electric field in order to distinguish between adhesion of medium (510) to the sensor head (110) and at least partial coverage of the sensor head with the medium.

12. Limit level sensor (100) according to one of the preceding claims, wherein the sensor electronics (120) are configured to detect a coverage of at least part of the sensor head (110) based on a conduction measurement and / or conductivity measurement.

13. The limit level sensor (100) according to any one of the preceding claims, further comprising: a process connection (130) for attaching the limit level sensor to a container (500, 505); and a sealing region (132) for sealing the process connection; and wherein the sealing region (132) is at least partially formed from amorphous metal and / or at least partially coated with amorphous metal.

14. Use of a limit level sensor (100) which is at least partially made of amorphous metal for determining a limit level of a medium (510).

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