Radar Fill Level Gauge with Integrated Limit Sensor

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Solution Overview

Problem

Radar fill level measuring devices face challenges in accurately detecting the maximum fill level and warning for excessive fill conditions, especially when the sensor is flooded or in close proximity to the filling material, due to ambiguous signals and decreased measurement accuracy.

Innovation Solution

Incorporating a limit level sensor unit that detects the minimum distance between the filling material surface and the radar antenna, allowing for reliable detection of excessive fill levels and outputting a warning signal, even when the radar sensor unit is flooded, using various methods such as vibration, conductive, or capacitive measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a radar sensor unit is used to measure fill level, then measurement capability is provided, but measurement reliability deteriorates when the sensor is submerged or in close proximity to the filling material

Engineering Contradiction:

Improvefill level detection accuracyVSAvoidmeasurement reliability in flooded conditions

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent combines a radar sensor unit with a limit level sensor unit in a single integrated device. The radar sensor provides continuous fill level measurement while the limit level sensor detects when the filling material reaches a critical proximity to the radar antenna. This merging of two different sensing technologies allows the system to maintain reliable operation even when the radar sensor alone would fail in flooded conditions.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If historical data functions are used to track targets, then target recognition is improved, but the system cannot provide reliable detection when first activated

Engineering Contradiction:

Improvetarget recognition reliabilityVSAvoidtime to achieve reliable detection

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The limit level sensor unit provides preliminary detection capability that works immediately upon activation, before any historical data from the radar sensor could be accumulated. By detecting the presence of filling material at a critical threshold using the limit level sensor, the system can provide reliable warnings from the first moment of operation, eliminating the delay associated with radar-based historical data analysis.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If the radar antenna is positioned close to the filling material surface, then measurement range is reduced, but detection accuracy for maximum fill level is improved

Engineering Contradiction:

Improvemaximum fill level detection accuracyVSAvoidmeasuring range

Core Design Contradiction:

Measurement precisionVSLength of moving object

Solution Approach 1:

The limit level sensor unit acts as an intermediary between the radar antenna and the filling material. It provides an additional detection layer that monitors when the filling material approaches the radar antenna at close proximity. This allows the system to benefit from close-range radar measurement accuracy while the limit level sensor compensates for the reduced measuring range by providing early warning before the material reaches critical levels.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Ensures accurate detection of fill levels and timely warnings for overfilled conditions, maintaining measurement reliability and accuracy by utilizing additional sensors to complement radar sensor units, especially in close-range or flooded scenarios.

Implementation Method 1

a radar antenna for emitting a measurement signal towards the surface of the contents

Methodology Applied

Scientific EffectRadar: Radar

Implementation Method 2

the radar sensor unit is configured to determine the level of the contents

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Implementation Method 3

using various methods such as vibration, conductive, or capacitive measurements

Methodology Applied

Scientific EffectVibration measurement: Vibration

Implementation Method 4

using various methods such as vibration, conductive, or capacitive measurements

Methodology Applied

Scientific EffectCapacitive measurement: Capacitance

Data Source

PatentEP3073229B1Radar fill level measuring device with integrated limit level sensor

Publication Date: 2022.06.22 VEGA GRIESHABER GMBH & CO

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AI summary

The invention relates to a radar level gauge (10) comprising a radar sensor unit (12) with a radar antenna (13) for emitting a measurement signal (14) towards the surface (15) of the contents. The radar level gauge (10) also comprises a limit level sensor unit (12) designed to determine the fill level (16) of the contents (17). The limit level sensor unit (12) is designed to detect when the fill level falls below a minimum distance (18) between the surface of the contents (15) and the radar antenna (13). Furthermore, the invention relates to a radar antenna assembly (50) for a radar level gauge (10), comprising a radar antenna horn (51) with a housing (20) and/or a cover (22) and a limit level sensor unit (12). At least a portion of the limit level sensor unit (12) is arranged on or integrated into the housing (20) or the cover (22).