Bulk Material Hopper Radar Level Sensing for Accurate Metering
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Solution Overview
Problem
Existing metering and weighing devices for cereal products face challenges in reliably determining the filling level due to density dependence and malfunctions from factors like grain size, flow characteristics, and interference from dust and material sticking, especially when using capacitive or light barrier sensors.
Innovation Solution
Employing a coherent radar sensor to measure the filling level in a bulk material container, which accounts for interference and reflections by using an initial measurement to subtract background signals, allowing precise level detection even during continuous material feed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If capacitive level sensors are used to monitor filling level, then the filling level can be determined independently of density, but the sensors are prone to malfunction due to sticking of material
Solution Approach 1:
The patent replaces mechanical/capacitive contact-based level sensors with a radar-based electromagnetic measurement system. The radar sensor emits electromagnetic waves that penetrate the bulk material without physical contact, eliminating the sticking problem inherent in capacitive sensors while maintaining accurate level measurement capability.
Solution Approach 2:
The patent introduces electromagnetic waves as an intermediary medium for level measurement. Instead of direct contact between the sensor and bulk material (as in capacitive sensors), the electromagnetic waves serve as a non-contact intermediary that carries measurement information through the material without being affected by material adhesion.
2Measurement precision
If light barriers are used for level measurement, then the filling level can be monitored at different heights, but the light barriers are prone to malfunction due to dust and sticking of material
Solution Approach 1:
The patent substitutes optical light barrier systems with radar-based electromagnetic measurement. Unlike light barriers that are easily blocked by dust and require clear paths, radar waves can penetrate dust and bulk material effectively, providing reliable level measurement in harsh environments without being blocked by particulate matter.
Solution Approach 2:
The patent changes the measurement parameter from optical (light) to electromagnetic (radar waves). This parameter change allows the system to operate effectively in dusty environments where light barriers fail, as radar waves have longer wavelengths that can penetrate dust and aerosols that would block visible light.
3Quantity of substance
If force transducers are used to determine filling level, then weight measurement is available, but the measurement depends on density and other characteristics such as grain size and flow characteristics
Solution Approach 1:
The patent segments the measurement functions by using separate systems: force transducers for weight measurement and radar sensors for level measurement. This segmentation allows each system to perform its specialized function optimally without the other's limitations, enabling independent and accurate determination of both mass and volume.
Solution Approach 2:
The patent introduces electromagnetic waves as an intermediary for level measurement, independent of the mechanical weight measurement system. This intermediary approach allows level determination based on physical distance rather than weight, eliminating dependence on material density and characteristics.
4Measurement precision
If multiple sensors are used to account for various measurement parameters, then measurement accuracy improves, but the device complexity increases
Solution Approach 1:
The patent makes the radar sensor multi-functional by demonstrating its capability to perform both level measurement and, when combined with weight data, density determination. This universality eliminates the need for separate specialized sensors for different measurement parameters, reducing overall system complexity while maintaining comprehensive measurement capability.
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
Provides a robust and cost-effective solution for accurately estimating the filling level, enabling closed-loop control of material delivery and reducing reliance on manual adjustments, even in compact and reflective environments.
Implementation Method 1
a radar sensor which is attached to the bulk material container at the upper side and generates a beam cone which is directed downwards into the inside of the container, in order to determine a level of the bulk material
Implementation Method 2
The frequency difference between the emitted radar signal and the one which is thrown back by the object is then a measure for the so-called time-of-flight and thus for the distance between the radar sensor and the object
Implementation Method 3
coherent radar sensor to measure the filling level in a bulk material container, which accounts for interference and reflections by using an initial measurement to subtract background signals
Data Source
AI summary
A metering and/or weighing device includes a bulk material container with a bulk material inlet and a bulk material delivery. The latter is configured to deliver bulk material which is present in the bulk material container, in intervals in a metered and/or controlled manner. The metering and/or weighing device has a radar sensor which is attached to the container at the upper side and generates a beam cone which is directed downwards into an inside of the container, in order to determine a level of the bulk material which is present in the container.