Modular Level Sensor Calibration Before Final Assembly
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Solution Overview
Problem
The logistical complexity of manufacturing and calibrating modular level measuring devices, particularly in legal metrology applications, is high due to the need for a calibration report for the entire device, which requires a complex calibration process.
Innovation Solution
A method for manufacturing and calibrating modular level measuring devices that involves connecting the transmission module to the sensor module, calibrating the sensor module on a calibration measuring section, and creating a calibration function based on recorded received variables, allowing the electronic module to be connected only during final assembly, thus simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the entire modular level measuring device is calibrated together to ensure measurement accuracy, then the calibration precision is improved, but the manufacturing and calibration process complexity increases
Solution Approach 1:
The calibration process is segmented into two independent parts: sensor module calibration and electronic module configuration. The sensor module is calibrated separately on a calibration measuring section to determine the calibration function, while the electronic module is configured separately with installation height parameters. This segmentation resolves the contradiction by maintaining calibration precision through separate precise calibration while reducing overall process complexity through independent processing of modules.
Solution Approach 2:
The sensor module calibration is performed as a preliminary action before final device assembly. The calibration function is determined in advance during sensor module calibration, and the electronic module is pre-configured with installation height. These preliminary actions eliminate the need for complex integrated calibration of the entire device, as the calibrated sensor module can be directly integrated with the pre-configured electronic module.
2Measurement precision
If all modules are calibrated together during final assembly, then the calibration accuracy is improved, but the production efficiency deteriorates
Solution Approach 1:
The sensor module calibration is performed as a preliminary action before final device assembly. The calibration function is determined in advance during sensor module calibration, and the electronic module is pre-configured with installation height. These preliminary actions eliminate the need for complex integrated calibration of the entire device, as the calibrated sensor module can be directly integrated with the pre-configured electronic module.
Solution Approach 2:
The calibration process is segmented into two independent parts: sensor module calibration and electronic module configuration. The sensor module is calibrated separately on a calibration measuring section to determine the calibration function, while the electronic module is configured separately with installation height parameters. This segmentation resolves the contradiction by maintaining calibration precision through separate precise calibration while reducing overall process complexity through independent processing of modules.
3Productivity
If the sensor module is calibrated separately before final assembly, then the production efficiency is improved, but the calibration complexity increases
Solution Approach 1:
The calibration process is segmented into two independent parts: sensor module calibration and electronic module configuration. The sensor module is calibrated separately on a calibration measuring section to determine the calibration function, while the electronic module is configured separately with installation height parameters. This segmentation resolves the contradiction by maintaining calibration precision through separate precise calibration while reducing overall process complexity through independent processing of modules.
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 method simplifies the manufacturing and calibration process by allowing the electronic module to be connected later, reducing logistical complexity and enabling precise calibration without needing additional modules to be calibrated, thus optimizing production efficiency.
Implementation Method 1
In the case of free-radiating radar (FMCW and pulse-time measurement), the transmission module essentially consists of a frequency-matched antenna into which the radar signal is coupled
Implementation Method 2
When using ultrasound, the measurement of the pulse transit time is the common measurement principle. In the case of radar, in addition to the pulse transit time principle (also known as 'Pulse radar' known) the FMCW principle ('Frequency Modulated Continuous Wave') is the common measuring principle
Implementation Method 3
the radar signal is sent or received via an antenna in the direction of the filling material according to the pulse-time-of-flight principle or according to the FMCW principle
Implementation Method 4
When using ultrasound, the measurement of the pulse transit time is the common measurement principle
Implementation Method 5
the measurement of the pulse transit time is the common measurement principle
Implementation Method 6
an electronics module which is designed to convert the sensor signal, taking into account a known installation height, into a standardized measured value signal
Data Source
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AI summary
The invention relates to a method for calibrating a modular fill-level gauge (1) which is based on a capacitive ultrasound-based or radar-based measuring principle and comprises a sensor module (11), an electronics module (12) and a transmission module (10). The method comprises the following method steps: connecting the transmission module (10) to the sensor module (11), subsequently calibrating (100) the sensor module (11), and teaching (200) the electronics module (12) with regard to the installation height (h). This simplifies calibration of the fill-level gauge (1) since the calibration does not have to be applied to the entire fill-level gauge (1) but merely to the sensor module (11). As a result, a corresponding calibration measurement section has to be provided only at the location of manufacture of the sensor module and not additionally at the location of final manufacture at which all the modules (10, 11, 12) of the fill-level gauge (1) are assembled. Accordingly, any creation of a calibration protocol ([di; dij]) is simplified as well.