Transit-Time Fill-Level Sensor Echo Shape Analysis
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Solution Overview
Problem
Existing fill-level measuring technologies face challenges in accurately determining the topography of bulk material surfaces in containers, particularly in distinguishing the filling material reflection from other echoes and achieving spatial resolution for a three-dimensional image, which is essential for precise fill volume calculation and container tilt considerations.
Innovation Solution
A fill-level measuring device that utilizes a computing unit to analyze the shape of echo signals from transit-time sensors, allowing for the determination of topography information, including the presence of charge cones or discharge funnels, and enabling accurate fill volume calculations even when the container is tilted, by evaluating echo shapes and incorporating additional environmental information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional transit-time sensors are used to measure fill level, then the measurement can be performed with simple equipment, but the spatial resolution is insufficient to generate a three-dimensional image of the filling material surface
Solution Approach 1:
The patent divides the measurement task into multiple independent resolution cells arranged in a grid pattern. Each resolution cell is measured by evaluating specific components of the echo signal corresponding to different spatial regions. This segmentation allows the system to achieve three-dimensional imaging capability by combining measurements from multiple cells, effectively resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent transitions from traditional one-dimensional fill level measurement to two-dimensional surface topology mapping by introducing spatial resolution cells in multiple directions. The system evaluates echo signals to determine not only the distance to the filling material surface but also the spatial distribution across different resolution cells, enabling three-dimensional image generation and improving spatial resolution without proportionally increasing overall system complexity.
2Loss of information
If the sensor measures only the distance to the filling material surface, then the calculation is simple, but the topography of the bulk material surface cannot be determined
Solution Approach 1:
The patent segments the echo signal into multiple components corresponding to different spatial resolution cells. By evaluating each component separately and mapping it to its corresponding resolution cell, the system extracts topography information about the bulk material surface while maintaining manageable signal processing complexity through systematic decomposition of the measurement task.
Solution Approach 2:
The patent creates a virtual three-dimensional model of the filling material surface by copying the echo signal characteristics into a grid of resolution cells. This virtual representation allows the system to determine surface topography and geometry without physically contacting the material, preserving information about the bulk material surface while avoiding complex physical measurement systems.
3Measurement precision
If the filling material surface is uneven, then the echo shape changes and provides topography information, but it becomes difficult to unambiguously distinguish the filling material reflection from other echoes
Solution Approach 1:
The patent segments the echo signal into multiple resolution cells, allowing the system to distinguish between reflections from the filling material surface and other echoes by spatially distributing the signal components. This segmentation enables unambiguous identification of the filling material reflection even when the surface is uneven, as each resolution cell can be independently analyzed for its echo characteristics.
Solution Approach 2:
The patent applies local quality analysis by evaluating the echo signal characteristics specific to each resolution cell. By determining which resolution cells contain filling material reflections and analyzing their local echo shapes, the system can accurately identify the filling material surface even in the presence of an uneven surface, improving measurement precision while managing echo differentiation difficulty through localized analysis.
Data Source
AI summary
A transit-time fill-level measuring device for measuring the fill level of a filling material in a container is stated, in which transit-time fill-level measuring device information about the topography of the filling material surface is determined on the basis of the shape of a single echo curve of the receiving signal. From this the fill volume can then be derived.