Virtual Array Radar Mapping for Bulk Solid Level Measurement
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Solution Overview
Problem
Current methods for measuring the content of bulk solid inventory in bins, such as silos, face challenges due to unfavorable conditions like dust, extreme temperatures, and complex geometries, leading to inaccuracies and reliability issues with existing sensors.
Innovation Solution
A system utilizing a plurality of transmitters and receivers distributed aerially above the bin content, which transmit pulses of wave energy and receive echoes to transform signals into measured distances, using correlators and beamformers to compute the direction and location of the upper surface, allowing for accurate three-dimensional mapping of the content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic level sensors are used to measure bulk solid inventory, then the measurement range is limited and performance deteriorates in the presence of dust
Solution Approach 1:
The patent replaces mechanical contact-based sensors (yo-yo sensors) and acoustic sensors (ultrasonic sensors) with electromagnetic radar sensors that measure bulk solid levels without physical contact. The radar sensors transmit electromagnetic waves that reflect off the bulk material surface, allowing measurement through dust and adverse atmospheric conditions without mechanical wear or clogging issues.
Solution Approach 2:
The patent uses electromagnetic waves in the frequency range of 0.3 GHz to 100 GHz that can penetrate dust and adverse atmospheric conditions. The electromagnetic waves are not significantly affected by dust particles, allowing reliable measurement in environments where ultrasonic waves would be scattered or absorbed by dust interference.
2Measurement precision
If radar level sensors are used to measure bulk solid inventory, then measurement accuracy improves, but device complexity and cost increase
Solution Approach 1:
The patent divides the measurement task into multiple independent radar sensors positioned at different locations around the bin, each measuring local surface height. This segmentation allows the system to handle complex geometries and coning phenomena by combining multiple simple measurements rather than using a single complex sensor system.
Solution Approach 2:
The patent transitions from single-point height measurement to three-dimensional surface mapping by distributing multiple radar sensors spatially around the bin. The system measures surface height at multiple locations and combines these measurements to create a comprehensive 3D model of the bulk material surface, enabling accurate volume calculation for complex geometries.
3Device complexity
If conventional level sensors are used, then simple point measurement is achieved, but accuracy deteriorates in the presence of coning and complex geometries
Solution Approach 1:
The patent divides the measurement task into multiple independent radar sensors positioned at different locations around the bin, each measuring local surface height. This segmentation allows the system to handle complex geometries and coning phenomena by combining multiple simple measurements rather than using a single complex sensor system.
Solution Approach 2:
The patent creates a universal measurement system that can accurately measure various bulk material geometries (cones, piles, settled surfaces) using the same radar sensor configuration. The system processes measurements from multiple sensors to generate three-dimensional surface maps that accurately represent any surface configuration, making the system universally applicable to different bin geometries and material types.
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 approach provides accurate and reliable measurement of the content height and volume in bins, overcoming the limitations of existing sensors by mapping the upper surface in two dimensions and handling complex geometries and coning phenomena.
Implementation Method 1
transmitting respective pulses of wave energy towards an upper surface of the content; and a plurality of receivers for receiving an echo of each pulse
Implementation Method 2
The height of the content is inferred from the round-trip travel time
Data Source
AI summary
A system for measuring the height of bin contents includes transmitters for transmitting pulses of wave energy towards the upper surface of the contents and receivers for receiving echoes of the pulses and producing corresponding signals. The transmitters and receivers are distributed aerially above the contents. The system also includes a processing apparatus, for using the received signals to map the upper surface, that includes correlators that correlate pulse waveforms with the signals, and a beamformer. In one embodiment, the beamformer computes, from the signals considered as corresponding to echoes, of pulses from fewer synthetic transmitters, received at a synthetic receiver array, respective directions of arrival of the signals. In another embodiment, the beamformer computes respective directions of transmission and arrival of the signals, and the processing apparatus also includes a processor that selects, according to the computed transmission and arrival directions, which signals to use for the mapping.