Radar fill-level sensor with remote radar unit

Abstract

The invention relates to a radar measuring device (100) which is designed to determine a fill level or a limit level in an industrial or private environment and has at least one sensor unit (110) for detecting and emitting measurement data, evaluation electronics (120) for receiving and evaluating the measurement data, and an interface (130) between the at least one sensor unit (110) and the evaluation electronics (120) for exchanging the measurement data. The at least one sensor unit (110) is arranged remotely from the evaluation electronics (120).

Description

VEGA GRIESHABER KG Our ref.: V11141WO / CGS Radar level sensor with separate radar unit TECHNICAL AREA

[0001] The present disclosure relates to measurement technology for process automation. In particular, the present disclosure relates to a radar measuring device for determining a fill level or a limit level in an industrial or private environment and the use of a radar measuring device for fill level and / or limit level measurement for process automation in an industrial or private environment. BACKGROUND Radar level sensors are frequently used in industrial and private settings to determine specific process parameters, for example, in process measurement technology and factory automation. A conventional radar level sensor consists of an antenna system mounted on the sensor electronics housing. The electronic components of the radar unit are located on the main electronics of the radar level sensor. SUMMARY

[0002] It is an object of the present invention to provide an improved radar measurement system with increased operational flexibility and measurement accuracy for process measurement.

[0003] This problem is solved by the features of the independent patent claim. Further developments of the invention are described in the dependent claims and the following description of embodiments.

[0004] A first aspect of the present disclosure relates to a radar measuring device designed for determining a fill level or a limit level in an industrial or private setting, comprising at least one sensor unit, evaluation electronics, and an interface. The at least one sensor unit is configured to acquire and transmit measurement data, and the evaluation electronics are configured to receive and evaluate the measurement data from the at least one sensor unit. The at least one sensor unit is arranged remotely from the evaluation electronics. The interface is arranged between the at least one sensor unit and the evaluation electronics and is used for exchanging data. CGS:YW the measurement data is set up between at least one sensor unit and the evaluation electronics.

[0005] The sensor unit for a radar measuring device is a radar unit that transmits and receives a radar signal or a measurement signal to detect a measured quantity, such as the fill level and / or limit level of a substance. The sensor unit may, for example, include a radar chip that converts measurement signals reflected by the substance into electrical signals to acquire the measurement data. The sensor unit or radar unit may consist of an antenna system, a transmitter / receiver unit, an analog-to-digital converter, and / or a digital communication interface to the evaluation electronics as the main electronics.

[0006] As the main electronics, the evaluation electronics can control the radar unit, receive and process the digitized radar signal, and provide external communication for the radar sensor.

[0007] For example, the radar measuring device can be a radar level sensor with a remote radar unit or a remote radar chip. Advantageously, at least one sensor unit and the evaluation electronics can be spatially separated. This allows for a low profile and thus a compact design for the sensor unit or radar unit, which, for example, includes a radar chip and an antenna, without having to integrate complex evaluation electronics as the main electronics.

[0008] For example, at least one sensor unit can be separable and arranged separately from the evaluation electronics. Thus, the separable sensor unit, which is spatially separated from the evaluation electronics, can, for example, have a different housing material and / or a different seal to protect against the ingress of aggressive substances than the evaluation electronics. Furthermore, the separable sensor unit can be designed to be pressure-tight, intrinsically safe, or explosion-proof, unlike the evaluation electronics, for example, by incorporating explosion-proof circuitry. Finally, the separable sensor unit can be made of a material with a different chemical resistance than the evaluation electronics, for example, to prevent the ingress of aggressive substances when used in a specific measurement environment.When connecting the detachable sensor unit to the evaluation electronics, the sensor unit may have a different cable connection, for example with a durable sheath and / or in the form of an explosion-proof connector at the cable end facing the sensor unit.

[0009] According to one embodiment of the present disclosure, the interface can be set up for the wired or wireless exchange of measurement data between the at least one sensor unit and the evaluation electronics.

[0010] For example, the interface can be implemented as a cable connection. For instance, at least one sensor unit and the evaluation electronics can be housed in a separate enclosure and connected only via a cable. Communication between the radar unit and the evaluation electronics can be digital or wired.

[0011] The radar unit can be mounted suspended from a cable or suspended from a fixed surface. For example, the radar unit, and thus the radar signal from the radar unit, can always be oriented perpendicular to the surface of a liquid. Hardware components of varying quality can be used in the front end, for example, in the at least one sensor unit, which may have high requirements for temperature stability and explosion protection, and in the back end, for example, in the evaluation electronics, which may have lower requirements.

[0012] According to a further embodiment of the present disclosure, the interface to the power supply for the at least one sensor unit can be set up by means of the evaluation electronics.

[0013] According to a further embodiment of the present disclosure, the interface can be designed to carry out the exchange of measurement data and the power supply between the at least one sensor unit and the evaluation electronics by means of a common cable or by means of a plurality of cables.

[0014] Thus, the radar chip can be powered via a cable from the evaluation electronics, which serve as the main electronics. For example, buffer capacitors can be incorporated into the main electronics. Power supply and communication, such as for exchanging measurement data, can take place between the sensor unit and the evaluation electronics via the same or separate cables.

[0015] Alternatively, the exchange of measurement data and the power supply between at least one sensor unit and the evaluation electronics can be implemented wirelessly. For example, wireless power supply can be achieved through inductive charging, energy harvesting, resonant inductive charging, or microwave transmission.

[0016] According to a further embodiment of the present disclosure, the at least one sensor unit can have an elongated shape. The evaluation electronics can be mounted at one end of the at least one sensor unit via the interface.

[0017] Alternatively, the sensor unit can have a different shape. For example, the sensor unit can be designed as a horn antenna.

[0018] According to a further embodiment of the present disclosure, the at least one sensor unit can have an antenna and be pivotably mounted on the evaluation electronics.

[0019] It may be provided that only the radar chip can be located or arranged in a swiveling sensor unit of the radar measuring device.

[0020] According to a further embodiment of the present disclosure, the interface may have a holder which may be designed to fix the antenna of the at least one sensor unit after pivoting it by a certain angle to capture the measurement data.

[0021] For example, the bracket can be designed as a rotary handle or a sliding handle, while the swiveling antenna or sensor unit can have a fastening element, such as a pin or a screw. The bracket can have a slot, for example in a radial shape, or a recess. For example, the pin of the swiveling sensor unit can engage in the slot or be designed to slide along the slot. The bracket can serve to secure the sensor unit after it has been swiveled through a specific angle and aligned in a direction with the contents.

[0022] According to a further embodiment of the present disclosure, the at least one sensor unit can be arranged at least partially inside a container and the evaluation electronics outside the container.

[0023] Since the evaluation electronics are located separately from the radar unit, the respective assemblies for the radar unit and the evaluation electronics can advantageously always be positioned in the optimal location. Thus, the radar chip can be positioned inside the container or tank when measuring the fill level or limit level.

[0024] According to a further embodiment of the present disclosure, the at least one sensor unit may have a transmitter and a receiver which are separately They should be designed and configured to form the individual sensor unit for connection to the evaluation electronics.

[0025] For example, the transmitter and receiver of the sensor unit can be spatially separated, such as at opposite ends of an elongated microwave cabinet of the radar sensor. By connecting the transmitter and receiver to the common evaluation electronics, a reversal of their functions can be achieved.

[0026] Alternatively, at least one sensor unit can have a transmit and receive module in which the transmitter and receiver are integrated or integrally formed.

[0027] According to a further embodiment of the present disclosure, the evaluation electronics may have a display which is set up to display the evaluated measurement data or the evaluation data.

[0028] According to a further embodiment of the present disclosure, the evaluation electronics may further comprise a communication module which is equipped to communicate the evaluated measurement data or the evaluation data via a radio connection.

[0029] According to another embodiment of the present disclosure, the communication module may include a LoRa chip or an NB-IoT chip.

[0030] The evaluation electronics can be located outside the container, tank, or shaft using the LoRa / NB-IoT chip.

[0031] According to another embodiment of the present disclosure, the communication module may include a LoRa chip or an NB-IoT chip.

[0032] According to a further embodiment of the present disclosure, the at least one sensor unit and the evaluation electronics can be arranged together in one housing.

[0033] Since the radar sensor is located separately from the evaluation electronics or main electronics, the main electronics can be positioned outside the housing containing the display in an accessible location. For example, with a swiveling radar antenna, the electronics housing can remain unchanged, while the radar chip and antenna are movable. The display can be positioned at a specific location. The radar unit can remain fixed, while the housing can be tilted.

[0034] According to a further embodiment of the present disclosure, the at least one sensor unit can have a plurality of sensor units which can be arranged separately from one another and remotely from the evaluation electronics and can be configured for connection to the single evaluation electronics.

[0035] For example, multiple or two radar chips can be used for a microwave barrier, with the two microwave chips and evaluation electronics forming a single microwave barrier. This enables synchronization between the transmitter and the receiver.

[0036] Unlike a radar speed gun, where at least one sensor unit and the evaluation electronics are housed in a separate casing and connected only by a cable, multiple sensor units can be connected to a single, shared evaluation electronics unit. This allows for simple synchronization between the radar units. Furthermore, the shared evaluation electronics enable the function to be reversed, eliminating the need for separate transmitters and receivers.

[0037] A first aspect of the present disclosure relates to the use of a radar measuring device for level and / or limit level measurement for process automation in an industrial or private environment.

[0038] The term "process automation in industrial environments" refers to a subfield of engineering that encompasses measures for operating machines and systems without human intervention. One goal of process automation is to automate the interaction of individual components within a plant in industries such as chemicals, food, pharmaceuticals, petroleum, paper, cement, shipping, or mining. A wide variety of sensors can be used for this purpose, specifically adapted to the requirements of the process industry, such as mechanical stability, resistance to contamination, extreme temperatures, and extreme pressures. Measurement data from these sensors is typically transmitted to a control room where process parameters such as fill level, limit level, flow rate, pressure, and density are monitored, and settings for the entire plant can be adjusted manually or automatically.

[0039] A subfield of process automation in industrial environments concerns the logistics automation of plants and the logistics automation of supply chains. Distance and angle sensors are used in logistics automation to control processes within or Automation can occur outside of a building or within a single logistics facility. Typical applications include baggage and freight handling at airports, traffic monitoring (toll systems), retail, parcel distribution, and building security (access control). What these examples have in common is that presence detection combined with precise measurement of an object's size and location is required by the respective application. Sensors based on optical measurement methods using lasers, LEDs, 2D cameras, or 3D cameras that capture distances using the time-of-flight (ToF) principle can be used for this purpose.

[0040] Another subfield of process automation in industrial settings concerns factory / production automation. Applications for this can be found in a wide variety of industries, such as automotive manufacturing, food production, pharmaceuticals, 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 allow it to proceed without human intervention. The sensors used here and the specific requirements regarding measurement accuracy for capturing the position and size of an object are comparable to those in the previous example of logistics automation.

[0041] The terms used in the claims should be interpreted in such a way as to give them the broadest possible reasonable interpretation in accordance with the foregoing description. For example, the use of the article "a" or "the" when introducing an element should not be interpreted as excluding a multitude of elements. Likewise, the mention of "or" should be interpreted as including a multitude of elements, so that the mention of "A or B" does not exclude "A and B" unless it is clear from the context or the preceding description that only one of A and B is meant.Furthermore, the phrase "at least one of A, B, and C" is to be understood as one or more elements from a group of elements consisting of A, B, and C, and not 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. Moreover, the mention of "A, B, and / or C" or "at least one of A, B, or C" should be interpreted as encompassing each individual unit of the listed elements, e.g., A; each subset of the listed elements, e.g., A and B; or the entire list of elements A, B, and C.

[0042] Further embodiments of the present disclosure are described below with reference to the figures. The following description of the figures refers to Where the same reference symbols are used, they denote identical or similar elements. The representations in the figures are schematic and not to scale. BRIEF DESCRIPTION OF THE FIGURES

[0043] Fig. 1 schematically shows a radar measuring device according to one embodiment.

[0044] Fig. 2a schematically shows a sensor unit and evaluation electronics for a radar measuring device according to one embodiment.

[0045] Fig. 2b schematically shows a sensor unit and evaluation electronics for a radar measuring device according to one embodiment.

[0046] Fig. 3a schematically shows a radar measuring device according to one embodiment.

[0047] Fig. 3b schematically shows a radar measuring device according to a further embodiment.

[0048] Fig. 3c schematically shows a radar measuring device according to another embodiment.

[0049] Fig. 4 schematically shows the arrangement of a radar measuring device on a container according to one embodiment.

[0050] Fig. 5 schematically shows a radar measuring device with a plurality of sensor units according to one embodiment. DETAILED DESCRIPTION OF EXECUTION FORMS

[0051] Fig. 1 shows a radar measuring device 100, which is set up to determine a fill level or a limit level in an industrial or private environment and has at least one sensor unit 110, an evaluation electronics 120 and an interface 130.

[0052] The at least one sensor unit 110 is configured to acquire and transmit measurement data, while the evaluation electronics 120 are configured to receive and evaluate the measurement data from the at least one sensor unit 100. Evaluation data can be generated from the measurement data using the evaluation electronics 120. The at least one sensor unit 110 is detachable and arranged separately from the evaluation electronics 120.

[0053] In other words, the sensor unit 100 and the evaluation electronics 120 can be provided separately and thus arranged spatially apart. This allows for a low overall height, resulting in a compact sensor unit. This may be necessary if, for example, the sensor unit can be designed in the form of a radar unit with an antenna.

[0054] The interface 130 is arranged between the at least one sensor unit 110 and the evaluation electronics 120 and is designed for exchanging measurement data between the at least one sensor unit 110 and the evaluation electronics 120.

[0055] For example, interface 130 can be configured for wired exchange of measurement data between at least one sensor unit 110 and the evaluation electronics 120. For example, interface 130 can be in the form of a cable. Alternatively or additionally, interface 130 can be configured for wireless exchange of measurement data between at least one sensor unit 110 and the evaluation electronics 120, in particular from the at least one sensor unit 110 to the evaluation electronics 120. For example, the measurement data exchange or transmission can take place via Bluetooth, Wi-Fi, and / or infrared. The wired or wireless interface enables the evaluation electronics 120 to access the at least one sensor unit 110. The interface 130 can also be configured to supply power to at least one sensor unit 110 via the evaluation electronics 120. Furthermore, the interface 130 can be designed to facilitate the exchange of measurement data and the power supply between the at least one sensor unit 110 and the evaluation electronics 120 via a single cable or via multiple cables. In other words, the exchange of measurement data and the power supply between the sensor unit 110 and the evaluation electronics 120 can be carried out via a single cable or via two or more separate cables of the interface 130. Alternatively or additionally to the power supply via one or more cables at the interface 130, the power supply can be wireless, for example, by inductive charging, energy harvesting, resonant inductive charging, or microwave transmission.

[0056] The evaluation electronics 120 can have a display that is configured to show the evaluated measurement data or the evaluation data itself. The display can be positioned in an optimal location, without taking into account the arrangement of the remote sensor unit 110.

[0057] The evaluation electronics 120 can also have a power supply 125, which can provide energy for operating the measuring device, in particular the evaluation electronics 120 and, if necessary, via the interface 130 or the cable of the sensor unit 110.

[0058] Furthermore, the evaluation electronics 120 can also include a communication module 128, which is configured to communicate the evaluated measurement data via a radio link. The communication module 128 can, for example, include a LoRa chip or an NB-IoT chip.

[0059] As shown in Figures 2a and 2b, the radar unit or sensor unit 110 is separated from the sensor housing containing the main electronics 120 and connected via a communication line. The radar unit 110 is suspended from the line, while the main electronics 120 are located separately in the sensor housing. This allows the main electronics 120 to be mounted on a container ceiling, where, depending on the application, there are no high temperatures, abrasive media, or explosion protection requirements. Depending on the position of the line with the radar unit 110 at its end, the offset or measuring range can be adjusted purely mechanically. Due to the suspended mounting in Figure 2a, the radar signal from the radar unit 110 can be oriented perpendicular to the surface of the contents.

[0060] The radar unit 100 can be significantly smaller or more compact because the main electronics 120 can be housed separately. This allows for installation in confined spaces and increases the distance to the medium, which can have a positive effect on short-range measurement. For example, in manholes or metallic containers, it can be difficult for conventional radar level sensors to establish a radio connection. The main electronics 120 with radio communication can now be placed in a suitable location with reception, while the radar unit 110 remains with the medium 55. This suspended version can also offer an alternative design to curved horn antennas.

[0061] Fig. 2a shows that the sensor unit or radar unit 110 of the radar measuring device 100 can have an elongated shape. The evaluation electronics 120 can be mounted at one end of the at least one sensor unit 110 via the interface 130.

[0062] Fig. 2b shows that the sensor unit 110 can be detached or provided separately from the evaluation electronics 120.

[0063] Alternatively, at least one sensor unit 110, as shown in Fig. 3a, Fig. 3b and Fig. 3b, can have an antenna 115 and be pivotably mounted on and away from the evaluation electronics.

[0064] Since the radar antenna 115 can be mounted swivellingly on the housing, the radar chip can align itself with the antenna 115 of the sensor unit 110 and move during the swiveling process. move along with it. This allows either only the housing of the sensor unit 110 to be swivelled to achieve a better position for the display and operation, or only the antenna 115 to optimally detect the contents.

[0065] Accordingly, the interface 130 between the sensor unit 110 and the evaluation electronics 120 can have a holder 131, which can be designed to fix the antenna 115 of the at least one sensor unit 110 after it has been pivoted by a certain angle α to acquire the measurement data. The holder 131 can be designed as a rotary handle or a fastening element and may have a slot or recess 1311. For example, a pin can be provided on the pivotable sensor unit, which engages in the slot 1311 and is designed to be slidable along the slot 1311. The holder 131 can fix the antenna 115 either at a first position 115a, as shown in Fig. 3b, or at a second position 115b, for example, after it has been pivoted by the certain angle to acquire the measurement data in a certain orientation.

[0066] For example, Fig. 4 shows that the pivotable sensor unit 110 or antenna 115 can be attached to a container 50 by means of a connection adapter 119. The connection adapter 119, together with the bracket 131, can be configured to allow the direction of a measurement signal from the antenna 115 to be changed by pivoting the remote sensor unit 110 or antenna 115 by a predetermined angle. This is advantageous for the container 50, which may have a funnel-shaped bottom and on which the radar measuring device 100 can be mounted laterally at the top. At the first position 115a, the antenna 115 can be oriented vertically downwards. As a level-measuring device, the radar measuring device can thus measure the fill level of the contents 55 in the container 50, but not all the way to the lowest point of the container. By determining the height d of the container 50 and the horizontal distance d to be shifted, the angle a can be determined so that the measurement signal from the sensor unit 110 or .The antenna 115 can be aligned to the lowest point or the opening of the container.

[0067] The sensor unit 110 can be located at least partially inside the container 50, and the evaluation electronics 120 can be located outside the container 50. The spatially separated arrangement of the sensor unit 110 and the evaluation electronics 120 is also shown in Fig. 5.

[0068] Advantageously, the respective hardware components can be of different quality grades used in the front end, for example for the sensor unit 110, and in the back end, for example for the evaluation electronics 120. For example, high requirements may be placed on the front end, while lower requirements may apply to temperature stability and / or explosion protection.

[0069] In Fig. 1, the at least one sensor unit 110 can have a transmitter 111 and a receiver 112, which are provided separately and can be configured to form the single sensor unit 110 for connection to the evaluation electronics 120, as shown on the left in Fig. 5. Alternatively, the at least one sensor unit 110 can have a transmit and receive module 113 in which the transmitter and the receiver can be integrated and formed in one piece, as shown in the center of Fig. 5.

[0070] Furthermore, Fig. 5 shows that at least one sensor unit 110, or at least one sensor unit 110, can comprise several or a plurality of sensor units, for example three sensor units, which are arranged separately from one another and remotely from the evaluation electronics 120 and are configured for connection to a single evaluation electronics unit 120. Alternatively, the at least one sensor unit 110 and the evaluation electronics unit 120 can be arranged together in one housing.

[0071] For example, a radar light barrier can be configured as the radar measuring device 100 by means of a common main electronics unit 120 and three radar units 110. This design has the advantage that only one main electronics unit 120 is required, thus simplifying synchronization. It is also conceivable that each radar unit 110 operates as a transmitter, receiver, or alternately, depending on the operating mode. By using multiple radar units 110, several limit values ​​can be detected and made available as measured values ​​via a single main electronics unit 120. The individual radar units 110 could be connected via a bus system and expanded as needed.

[0072] It should be further noted that "comprehensive" and "comprising" do not exclude other elements or steps, and the indefinite articles "a" or "an" do not exclude a plurality. It should also be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference numerals in the claims are not to be considered limitations. List of reference symbols 50 containers 55 Filling material 100 radar measuring devices 110 sensor unit 111 stations 112 recipients 113 Transmit and receive module 115 Antenna 115a first position of the antenna 115b second position of the antenna 119 Connection adapters 120 evaluation electronics 125 Energy supply 128 Communication module 130 interface 131 Bracket 1311 slot a horizontal distance d height a angle

Claims

REQUIREMENTS 1. Radar measuring device (100), configured for determining a fill level or a limit level in an industrial or private environment, comprising: at least one sensor unit (110), configured for acquiring and transmitting measurement data, evaluation electronics (120), configured for receiving and evaluating the measurement data from the at least one sensor unit (110), and an interface (130); wherein the at least one sensor unit (110) is arranged remotely from the evaluation electronics (120); wherein the interface (130) is arranged between the at least one sensor unit (110) and the evaluation electronics (120) and is configured for exchanging the measurement data between the at least one sensor unit (110) and the evaluation electronics (120).

2. Radar measuring device (100) according to claim 1, wherein the interface (130) is provided for the wired or wireless exchange of the measurement data between the at least one sensor unit (110) and the evaluation electronics (120).

3. Radar measuring device (100) according to claim 1 or 2, wherein the interface (130) for the power supply for the at least one sensor unit (110) is provided by means of the evaluation electronics (120).

4. Radar measuring device (100) according to one of the preceding claims, wherein the interface (130) is designed to enable the exchange of measurement data and the power supply between the at least one sensor unit (110) and the evaluation electronics (120) by means of a common cable or by means of a plurality of cables.

5. Radar measuring device (100) according to one of the preceding claims, wherein the at least one sensor unit (110) has an elongated shape; and wherein the evaluation electronics (120) is mounted at one end of the at least one sensor unit (110) via the interface (130).

6. Radar measuring device (100) according to one of the preceding claims 1 to 4, wherein the at least one sensor unit (110) has an antenna (115) and is pivotably mounted on the evaluation electronics.

7. Radar measuring device (100) according to claim 6, wherein the interface (130) has a holder (131) which is designed to fix the antenna (115) of the at least one sensor unit (110) after pivoting by a certain angle (a) to capture the measurement data.

8. Radar measuring device (100) according to one of the preceding claims, wherein the at least one sensor unit (110) is arranged at least partially inside a container (50) and the evaluation electronics (120) is arranged outside the container (50).

9. Radar measuring device (100) according to one of the preceding claims, wherein the at least one sensor unit (110) comprises a transmitter (111) and a receiver (112) which are provided separately and are configured to form together the single sensor unit (110) for connection to the evaluation electronics (120); or wherein the at least one sensor unit (110) comprises a transmit and receive module (113).

10. Radar measuring device (100) according to one of the preceding claims, wherein the evaluation electronics (120) has a display which is configured to display the evaluated measurement data.

11. Radar measuring device (100) according to one of the preceding claims, wherein the evaluation electronics (120) further comprises a communication module (128) which is equipped to communicate the evaluated measurement data via a radio connection.

12. Radar measuring device (100) according to claim 11, wherein the communication module (128) comprises a LoRa chip or an NB-IoT chip.

13. Radar measuring device (100) according to one of the preceding claims, wherein the at least one sensor unit (110) and the evaluation electronics (120) are arranged together in a housing.

14. Radar measuring device (100) according to one of the preceding claims, wherein the at least one sensor unit (110) comprises a plurality of sensor units which are arranged separately from one another and remotely from the evaluation electronics (120) and are configured for connection to the single evaluation electronics (120).

15. Use of a radar measuring device (100) according to one of claims 1 to 14 for level and / or limit level measurement for process automation in an industrial or private environment.

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