Radar Sensor Filling Level Detection in Vacuum Sausage Production
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Solution Overview
Problem
Current filling level detection methods in filling machines, particularly for high vacuum systems, are prone to measurement errors due to condensate, droplet formation, steam, mist, and foam, and are unsuitable for clear or transparent filling media, leading to inaccurate or unreliable measurements.
Innovation Solution
A filling machine equipped with a radar sensor that sends electromagnetic waves to detect the filling level in the hopper, which is resistant to water droplets, condensate, and vacuum conditions, and can accurately measure the surface of clear media, using an antenna system and analysis unit to calculate the filling level based on the time of wave reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic sensors are used for filling level detection, then measurement can be performed in air medium, but measurement fails in vacuum conditions due to lacking carrier medium
Solution Approach 1:
The patent replaces ultrasonic sensors (acoustic/mechanical wave-based) with radar sensors (electromagnetic wave-based) for filling level detection. Electromagnetic waves do not require a material carrier medium and can propagate through vacuum, thereby resolving the measurement failure in vacuum conditions while maintaining measurement reliability across different environmental conditions.
Solution Approach 2:
The patent changes the fundamental measurement parameter from acoustic wave propagation time (ultrasonic) to electromagnetic wave propagation time (radar). This parameter change enables the measurement system to function in both atmospheric and vacuum environments, as electromagnetic waves are not dependent on material medium for propagation.
2Ease of operation
If laser time of flight sensors are used for filling level detection, then contactless measurement is achieved, but measurement errors occur due to condensate and droplet formation
Solution Approach 1:
The patent replaces laser time of flight sensors (optical) with radar sensors (electromagnetic). Radar waves at the operating frequency are not significantly affected by condensate and droplet formation, maintaining measurement precision while preserving the contactless measurement capability in challenging environmental conditions.
Solution Approach 2:
The patent changes the measurement wavelength from optical range (laser) to microwave/radar range. This parameter change makes the measurement less sensitive to condensate and droplet interference, as radar waves can penetrate or pass through such formations without significant scattering or absorption, thereby maintaining accuracy.
3Ease of operation
If laser time of flight sensors are used for transparent filling media, then contactless measurement is achieved, but the laser beam penetrates the media and cannot detect the surface accurately
Solution Approach 1:
The patent replaces laser sensors (optical) with radar sensors (electromagnetic) for measuring transparent filling media. Radar waves are effectively reflected by the surface of transparent media without penetrating through, enabling accurate surface detection while maintaining contactless operation.
Solution Approach 2:
The patent changes the measurement wavelength from optical to electromagnetic range. This parameter change fundamentally alters the interaction with transparent media: while optical waves penetrate transparent materials, electromagnetic radar waves are reflected by the surface, enabling accurate detection of transparent filling media surfaces.
4Productivity
If high vacuum is applied in the hopper for filling, then filling quality is improved, but steam and mist formation occurs leading to measurement errors
Solution Approach 1:
The patent replaces sensors sensitive to steam and mist (ultrasonic, optical) with radar sensors that are resistant to such environmental conditions. The electromagnetic waves used in radar measurement are not significantly affected by steam and mist formation, maintaining measurement precision while allowing high vacuum filling operations to proceed.
Solution Approach 2:
The patent changes the measurement approach from methods sensitive to phase changes and atmospheric conditions to electromagnetic wave-based measurement that is insensitive to steam and mist. This parameter change allows the system to maintain accurate filling level detection even when vacuum-induced steam and mist formation occurs during high-quality filling operations.
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
The radar sensor provides a simple and reliable, contactless method for continuous filling level detection, suitable for both open and closed hoppers, including high vacuum systems, reducing measurement errors and ensuring accurate filling levels even in challenging conditions.
Implementation Method 1
The radar sensor sends electromagnetic waves. These are reflected at the surface of the filling medium located in the hopper and are again received from the radar sensor.
Implementation Method 2
These are reflected at the surface of the filling medium located in the hopper and are again received from the radar sensor.
Implementation Method 3
the time of the electromagnetic waves and, thus, the distance to the filling medium is measured
Data Source
AI summary
The present disclosure relates to a filling machine and a method for filling of filling medium, in particular for the production of sausages with a hopper for accommodating filling medium, a conveyer for supplying the filling medium and a filling element, in particular a filling tube, as well as a device for measuring the filling level in the hopper. The device for measuring the filling level comprises a radar sensor.