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 the volumetric content of materials in tanks and vessels due to wide beamwidths, interference from obstacles, and the need for precise installation, especially in harsh environments, leading to inaccurate measurements and safety concerns.
Innovation Solution
The implementation of an imaging phased array radar system with adaptive beam steering and monopulse processing, which uses a narrow-beam scanning capability to create a 3D volumetric model, overcoming obstacles and providing precise measurements even in harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional radar antenna with wide beamwidth is used, then the radar can cover a larger area and detect more of the material surface, but the measurement precision deteriorates due to interference from obstacles and inability to resolve surface details
Solution Approach 1:
The patent segments the radar beam into multiple narrow beams arranged in a grid pattern, allowing the system to cover a large area while maintaining high measurement precision. Each narrow beam targets a specific region, enabling detailed surface mapping without the interference problems associated with wide single beams.
Solution Approach 2:
The patent transitions from conventional point-to-point level measurement to a two-dimensional grid of measurement points. By arranging beams in multiple rows and columns, the system creates a volumetric model of the material surface, adding spatial dimensionality to the measurement process and enabling precise mapping of surface profiles.
2Ease of operation
If the radar antenna is positioned close to the tank wall for convenient installation, then the ease of operation improves, but the reliability deteriorates due to interference from tank wall reflections and obstacles
Solution Approach 1:
The patent applies local quality by directing specific narrow beams toward suspected obstacle regions based on preliminary scanning data. Rather than uniformly treating all areas, the system adapts beam steering to locally compensate for obstacles, allowing reliable operation even when the antenna is positioned close to tank walls or other structures.
Solution Approach 2:
The system performs preliminary scanning to identify obstacle locations before conducting precise volumetric measurements. This preliminary action allows the radar to adapt its beam steering strategy, avoiding known interference sources and ensuring measurement reliability regardless of antenna position relative to tank walls.
3Device complexity
If conventional point-to-point level measurement is used, then the device complexity remains low, but the measurement precision deteriorates because it assumes a flat surface which is not true for viscous liquids and solids
Solution Approach 1:
The patent implements a transition from one-dimensional point-to-point level measurement to two-dimensional grid-based volumetric mapping. By measuring multiple points arranged in a grid pattern and calculating volumes between adjacent points, the system accurately captures surface profiles of viscous liquids and solids without requiring complex additional hardware.
Solution Approach 2:
The measurement process is segmented into discrete grid cells, with each cell's volume calculated from four surrounding measurement points. This segmentation approach enables accurate volumetric measurement of irregular surfaces by breaking down the complex surface into manageable geometric units, maintaining simplicity while improving precision.
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 material surfaces with high precision, reducing volumetric errors and enhancing safety in maritime and air transportation by providing a 3D model of the material surface, including height, slope, and horizontal dimensions, even in the presence of 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
the distance to the surface of the product can be determined based on the time between transmission of an electromagnetic signal and reception of the reflection thereof
Data Source
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.