Dynamic Fill Level Evaluation Using Process Feedback
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Solution Overview
Problem
Existing fill level measuring devices using the travel time principle face challenges in reliably identifying the wanted echo signal due to interference from disturbance echo signals, especially when the measurement conditions change or during processes that alter the container and fill substance, leading to potential misidentification and energy constraints in explosion-endangered areas.
Innovation Solution
A method where the echo curve or envelope curve is transmitted to a superordinate control unit for evaluation, allowing dynamic adaptation of the evaluation based on current process information, reducing the computational and energy burden on the fill level measuring device by considering the current process for plausibility checks and parameter selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wanted echo signal is identified using static methods or echo tracking, then the fill level can be determined, but the reliability decreases when measurement conditions change or disturbance echo signals are present
Solution Approach 1:
The evaluation is made dynamic by continuously adapting it based on current process information from the superordinate control unit. The system transitions from static evaluation methods to dynamic adaptation where evaluation parameters are adjusted in real-time according to the current process state, ensuring reliable wanted echo signal identification even when measurement conditions change.
Solution Approach 2:
The system implements feedback by using current process information from the superordinate control unit to continuously adjust the evaluation of the echo curve. The superordinate control unit provides feedback about the current process state, which is then used to adapt the evaluation parameters and improve the reliability of wanted echo signal identification.
2Ease of operation
If the echo curve is evaluated locally in the fill level measuring device, then the device is self-sufficient, but the energy consumption increases in explosion-endangered areas
Solution Approach 1:
The evaluation function is extracted from the fill level measuring device and relocated to the superordinate control unit. The echo curve is transmitted from the measuring device to the superordinate control unit for evaluation, thereby removing the computationally intensive evaluation process from the energy-constrained measuring device while maintaining its operational autonomy.
Solution Approach 2:
The superordinate control unit acts as an intermediary that receives the echo curve from the fill level measuring device, performs the evaluation using current process information, and returns the results. This intermediary approach allows the measuring device to remain simple and energy-efficient while still achieving accurate fill level determination.
3Productivity
If echo tracking is used to follow the wanted echo signal, then continuous fill level monitoring is possible, but the system fails when the wanted echo signal lies in the region of a disturbance echo signal
Solution Approach 1:
The system uses feedback from the superordinate control unit about the current process state to distinguish between wanted echo signals and disturbance echo signals. When the wanted echo signal lies in the region of a disturbance echo signal, the current process information provides feedback that helps correctly identify the wanted echo signal, preventing misidentification and maintaining accurate continuous monitoring.
Solution Approach 2:
The system performs preliminary action by obtaining current process information from the superordinate control unit before evaluating the echo curve. This preliminary information about the process state is used to prepare the evaluation parameters and criteria, enabling the system to correctly identify the wanted echo signal even in challenging conditions where disturbance echo signals are present.
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
This approach enhances accuracy and availability by ensuring the evaluation is always adapted to the current process, allowing reliable fill level determination even in situations where static methods fail, and reduces the energy and space requirements of the fill level measuring device.
Implementation Method 1
fill level is ascertained by registering and evaluating a so-called echo curve. Each measured value of the echo curve corresponds to the amplitude of an echo signal reflected on a surface at a certain distance
Implementation Method 2
The transmitter is, for example, an antenna apparatus, via which microwaves are transmitted
Implementation Method 3
ascertained an echo curve, which represents amplitude of the reflected back signal fractions as a function of travel time
Implementation Method 4
In the case of frequency difference measurement (FMCW—Frequency-Modulated Continuous Wave) a continuous microwave is transmitted, which is frequency modulated periodically and linearly. The frequency of a received echo signal has, consequently, compared with the frequency transmitted at the time of receipt a frequency difference, which depends on the travel time of the echo signal
Data Source
AI summary
The present disclosure relates to a method for determining fill level of a substance in a container using a measuring device working according to the travel time principle. The measuring device transmits signals to the fill substance and, based on signal fractions reflected back in the container, ascertains an echo curve. The echo curve is transmitted to a superordinate control unit, and an envelope curve enveloping the echo curve is created and transmitted to the superordinate control unit. The echo curve and envelope curve are evaluated by the superordinate control unit. A wanted echo signal of the echo curve and envelope curve is identified. During the determining of the fill level the fill substance and the container are subjected to a current process. Based on information concerning the current process, plausibility of the wanted echo signal is checked and the evaluation is dynamically adapted to the current process.