3D Fill Volume Measurement for Irregular Bulk Material Surfaces
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Solution Overview
Problem
Existing non-contact level measurement systems struggle to accurately determine the filling volume of solid materials in containers with complex geometries and inhomogeneous fill levels, as they are prone to ambiguities and angular errors, and require precise container geometry knowledge.
Innovation Solution
A radar-based level gauge combined with a 3D camera is used to create a three-dimensional fill level profile and determine the container's geometry, allowing for the calculation of filling volume by integrating digital beamforming principles like MIMO and utilizing 3D imaging to compensate for angular errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If digital beamforming methods like MIMO are used to create three-dimensional fill level profiles, then measurement precision is improved, but ambiguities and angular errors occur
Solution Approach 1:
The patent combines radar-based level gauge with digital beamforming capabilities into an integrated measuring system that can generate three-dimensional fill level profiles. This merging of functions allows the system to achieve both high measurement precision through virtual aperture enlargement and maintain reliability by processing multiple signal paths simultaneously to resolve ambiguities and angular errors.
2Ease of operation
If tank table-based fill volume determination is used, then ease of operation is improved, but it requires smooth horizontal surfaces which are only present with liquids
Solution Approach 1:
The patent transitions from two-dimensional tank table-based measurements to three-dimensional fill level profiling using digital beamforming. This dimensional enhancement allows the system to capture the complete surface topology of bulk materials, enabling accurate fill volume determination for both liquids and solids by accounting for surface irregularities, cones, and inhomogeneities that traditional methods cannot measure.
3Device complexity
If point level measurement is used for homogeneous liquids, then device complexity is reduced, but it is insufficient for inhomogeneous solid materials
Solution Approach 1:
The patent segments the measurement space into multiple directional beams using digital beamforming techniques. Instead of a single point measurement, the system divides the measurement field into multiple angular sectors, each providing fill level information from different directions. This segmentation enables accurate representation of inhomogeneous solid material surfaces while maintaining manageable system complexity through software-based signal processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate determination of filling volume in containers with complex geometries and inhomogeneous fill levels by providing a precise three-dimensional fill level profile and container geometry, overcoming ambiguities and angular errors.
Implementation Method 1
radar-based level gauge by means of which a three-dimensional level profile of the surface of the contents in the container can be created
Implementation Method 2
an antenna arrangement by means of which radar signals can be emitted towards the contents according to a digital beamforming principle, such as the MIMO principle, and by means of which corresponding received signals can be received after reflection of the radar signal at the surface of the contents
Implementation Method 3
a 3D camera by means of which at least one three-dimensional image of at least a partial area of the interior of the container can be captured
Data Source
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Figure 2
AI summary
The invention relates to a measuring system for determining a fill volume of a filling material (4) in a container (3). For this purpose, the measuring system comprises a 3D camera (2) and a radar-based fill-level measuring device (1). The 3D camera (2) is used to first capture at least one 3D image ([pi,j]) of at least one portion of the empty container interior. On the basis of the 3D images ([pi,j]), a data set or a digital spatial model is created which represents the geometry of at least this portion of the empty container interior. In order to create the required three-dimensional surface or fill-level profile (L(a, ꞵ)), the fill-level measuring device (1) is based on a digital beam forming principle, such as the MIMO principle. Therefore, the fill volume in the container (3) can be determined on the basis of the data set reflecting the geometry in the container interior, and on the basis of the fill-level profile (L(a, ꞵ)).