Fill Level Radar with Empty Profile Detection
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Solution Overview
Problem
Existing filling level measurement technologies face challenges in accurately determining the volume or mass of filling materials due to interference from container imperfections and external objects, leading to inaccurate measurements.
Innovation Solution
A method involving an empty profile detection mode to identify and account for imperfections in the container, using adjustable antenna directions and electronic beam control to generate echo curves, which are then used to create an imperfection profile, allowing for precise volume or mass determination by distinguishing between container reflections and filling material reflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If three-dimensional level measurement is used to measure surface topology, then volume or mass determination precision is improved, but device complexity increases due to mechanical tilting/rotating mechanisms or electronic beam control systems
Solution Approach 1:
The patent applies preliminary action by performing an empty profile detection mode before actual filling measurements. The system scans and stores the container's empty state profile, including all imperfections and external objects, in advance. This pre-acquired reference data is then used during volume/mass determination to distinguish between container reflections and filling material reflections, eliminating the need for complex real-time differentiation mechanisms.
Solution Approach 2:
The patent segments the measurement process into distinct operational modes: empty profile detection mode and filling measurement mode. It also segments the echo signals into different categories (container reflections vs. filling material reflections) by comparing current measurements against the stored empty profile. This segmentation simplifies the measurement approach by handling container and filling characteristics separately.
2Measurement precision
If scanning of the surface by tilting or rotating the antenna is performed, then surface topology measurement capability is improved, but ease of operation deteriorates due to mechanical control requirements
Solution Approach 1:
The patent replaces mechanical tilting or rotating mechanisms with electronic beam control systems. Instead of physically moving the antenna to scan different directions, the system uses electronic means to control the beam direction and scan the surface topology. This substitution eliminates complex mechanical control requirements while maintaining the ability to perform three-dimensional level measurement and surface topology detection.
3Reliability
If container imperfections and external objects are present, then measurement reliability deteriorates due to interference reflections, but adding correction mechanisms increases device complexity
Solution Approach 1:
The system performs preliminary scanning and storage of the container's empty state, including all imperfections and external objects, before actual measurements. This pre-acquired reference profile is used to identify and eliminate interference reflections during volume/mass determination, improving reliability without adding complex real-time correction mechanisms.
Solution Approach 2:
The patent creates a digital copy of the container's empty profile, including all imperfections and external objects, by scanning and storing the reference data. This copied reference profile is then used during measurements to distinguish between container-related reflections and filling material reflections, eliminating interference without requiring physical modification of the container or addition of complex correction hardware.
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 measurement accuracy by eliminating the effects of container imperfections and external objects, providing a more reliable determination of the volume or mass of filling materials.
Implementation Method 1
level radar devices are known which can be used for three-dimensional level measurement
Implementation Method 2
a transmission signal is emitted by the antenna of the fill level measuring device in different directions to the surface of the filling material and echo curves are detected
Data Source
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AI summary
A method for determining the volume or the mass of a filler (107), in which first of all an empty profile detection mode is undertaken in the absence of a filler and then a volume or mass determination mode is undertaken in the presence of a filler. In the empty profile detection mode, a defect profile is generated from the echo curves obtained by scanning the container surface. Said defect profile is then taken into consideration in the determination of the volume or the mass of the filler in the volume or mass determination mode. This makes it possible to determine volume or mass of the filler with greater accuracy.