Adaptive Radar Level Gauge for Unstable Tank Conditions

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Solution Overview

Problem

Radar level gauges in tanks face reliability issues due to unstable conditions such as power failures and interference, leading to inaccurate measurements and the need for frequent recalibration, which can result in significant financial losses.

Innovation Solution

A self-adaptive signal-processing algorithm is implemented in a tank level measurement system that retrieves and compares measurements, determines differences, and adjusts the current level identification based on thresholds to maintain accuracy and reliability during power interruptions and interference, eliminating the need for manual recalibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional radar level gauges are used in tank measurement systems, then the system offers flexibility and reduced maintenance in normal conditions, but the measurement reliability deteriorates under unstable conditions such as power failures and interference

Engineering Contradiction:
Improveflexibility and maintenance requirementsVSAvoidmeasurement reliability under unstable conditions
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The system stores reference level measurements in memory before power failures or unstable conditions occur. When the gauge resumes operation after a power interruption, it retrieves these previously stored measurements and compares them with current measurements to determine accurate levels without requiring recalibration. This preliminary storage of reference data enables the system to maintain reliability under unstable conditions while preserving the flexibility and reduced maintenance characteristics of conventional radar gauges.

Inventive Principle:
Principle #10Preliminary action

2Device complexity

If radar level gauges operate under unstable conditions without adaptation, then device simplicity is maintained, but measurement precision deteriorates due to interference and power failures

Engineering Contradiction:
Improvesystem simplicityVSAvoidlevel measurement accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The system continuously compares current level measurements with previously stored reference measurements from stable operating conditions. When measurements are taken after power failures or during unstable conditions, the system uses feedback from the stored reference data to identify and correct measurement errors. This feedback mechanism maintains measurement precision within acceptable thresholds without requiring complex recalibration procedures, thus preserving device simplicity while improving precision under unstable conditions.

Inventive Principle:
Principle #23Feedback

3Measurement precision

If manual recalibration is performed frequently to maintain measurement accuracy, then measurement precision is maintained, but productivity and time efficiency deteriorate

Engineering Contradiction:
Improvelevel measurement accuracyVSAvoidoperational efficiency and time loss
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

The radar level gauge system performs self-calibration by automatically comparing current measurements with reference measurements stored in memory from previously stable operating conditions. When the system detects that measurements are being taken under unstable conditions (after power failures or during interference), it autonomously identifies measurement errors and corrects them using the stored reference data, eliminating the need for manual recalibration. This self-service capability maintains measurement precision while completely eliminating the productivity loss and time consumption associated with frequent manual recalibration operations.

Inventive Principle:
Principle #25Self-service

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

The system ensures highly reliable and accurate tank level measurements by automatically adapting to unstable conditions, maintaining measurement accuracy within 0.5mm deviation, even during power failures and severe interference, thus preventing costly errors.

Implementation Method 1

One approach to measuring the amount of material in a tank involves non-contact radar sensing

Methodology Applied
Scientific EffectRadar: Radar

Implementation Method 2

radar signals are transmitted towards and reflected off the surface of material in a tank

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentEP2166318B1Method and apparatus for adaptively handling level measurements under unstable conditions
Publication Date: 2020.02.26 HONEYWELL INTERNATIONAL INC
  • EP2166318B1 patent drawingFigure 1
  • EP2166318B1 patent drawingFigure 2
  • EP2166318B1 patent drawingFigure 3

AI summary

A method includes retrieving (216) at least one first measurement associated with material (104) in a tank (102) from a memory (122) at a level gauge. The method also includes comparing (304) the at least one first measurement to at least one second measurement associated with the material in the tank. The method further includes determining (306) whether a difference between the at least one first measurement and the at least one second measurement exceeds a threshold. In addition, the method includes identifying a current level of the material in the tank in a first manner (308-312) if the difference does not exceed the threshold or a second manner (316-322)if the difference does exceed the threshold. The first manner could include correcting (312) a level measurement using the difference between the at least one first measurement and the at least one second measurement. The second manner could include identifying an offset value (318-320) based on differences between pairs of level measurements.