Phased-Array Radar Level Gauge for 3D Surface Mapping
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Solution Overview
Problem
Conventional radar level gauges face challenges in accurately measuring volumetric content in tanks and vessels due to wide beamwidths, interference from obstacles, and the need for precise installation, especially in harsh environments, leading to inaccuracies and safety concerns.
Innovation Solution
The implementation of an imaging radar level gauge system with adaptive beam steering and monopulse processing, utilizing a phased array antenna system that electronically steers narrow beams to create a 3D volumetric model, overcoming obstacles and providing precise measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional radar level gauges use wide beamwidth antennas, then the antenna can cover larger area, but measurement precision deteriorates due to interference from obstacles and inability to resolve surface profile
Solution Approach 1:
The patent divides the radar beam into multiple narrow beams using a phased array antenna system. Each antenna element generates a narrow beam, and by controlling the phase and amplitude of each element, the system creates multiple focused beams that scan across the surface. This segmentation of the beam into narrow, controllable components allows precise measurement while maintaining coverage area through electronic scanning.
Solution Approach 2:
The patent transitions from conventional single-point level measurement to three-dimensional surface mapping by introducing angular dimensions. The phased array system measures not only the depth of each beam but also the angular position, creating a 3D representation of the surface profile. This dimensional expansion allows the system to distinguish between actual surface variations and obstacles, resolving the precision-coverage contradiction.
2Ease of operation
If radar antenna is positioned close to tank wall or obstacles, then installation flexibility improves, but measurement reliability deteriorates due to signal interference and reflections
Solution Approach 1:
The patent applies local quality by directing narrow, focused beams only to specific regions of interest while maintaining the ability to avoid obstacles. The phased array system can independently control each beam's direction and focus, allowing the antenna to be positioned close to walls or obstacles while selectively illuminating only the desired measurement areas, thus maintaining both installation flexibility and measurement reliability.
Solution Approach 2:
The system uses feedback from the received signals to identify obstacles and adjust beam directions in real-time. By analyzing the reflected signals from multiple angles, the system can detect obstacles and automatically modify the scanning pattern to avoid them, ensuring reliable measurements even when the antenna is positioned in challenging locations near tank walls or internal structures.
3Device complexity
If conventional radar assumes flat surface, then calculation simplicity improves, but volumetric measurement precision deteriorates for viscous liquids and solids with non-flat surfaces
Solution Approach 1:
The patent performs preliminary action by mapping the complete three-dimensional surface profile before calculating volume. The phased array system first measures the depth and angular position of multiple beams to create a detailed surface model, then uses this pre-established 3D representation for accurate volume calculation. This preliminary surface characterization eliminates the need for flat surface assumptions and provides the foundation for precise volumetric measurements of complex surfaces.
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 system enables accurate, real-time measurement of volumetric data with enhanced precision, reducing errors and improving safety in harsh conditions by electronically steering beams to map uneven surfaces and obstructions.
Implementation Method 1
radar has been used as a type of non-contact product level gauge for several decades. A typical radar system can include a transmitter coupled to a radar antenna which is positioned above the product (e.g., a liquid or solid) for emitting electromagnetic wave signals to the product and a receiver coupled to the same antenna
Implementation Method 2
The transmitted electromagnetic signals are reflected at the surface of the product, and the reflected signals are received by a receiver or transceiver comprised in the radar level gauge
Implementation Method 3
an antenna system comprising an imaging phased array in an isolated antenna arrangement configured for monopulse processing for radar image resolution and mapping of a surface of a material. The imaging phased array provides a narrow-beam with beam scanning/steering
Data Source
Figure 1A~1C
Figure 2A
Figure 2B~3
AI summary
In an embodiment, a radar level gauge system can include an antenna system comprising an imaging phased array in an isolated antenna arrangement that supports monopulse processing for radar image resolution and mapping of a surface of a material. The imaging phased array can provide a narrow-beam with beam scanning/steering and can emit a transmit beam that scans the surface of the material and forms the mapping of the surface. The mapping can comprise a 3D volumetric model that can include an image of a surface profile of the surface based on signals returned from the surface. The imaging phase array and the antenna system are protected from condensation and contamination from chemicals and viscous materials.