Level measuring instrument for determining moisture content
10072961 ยท 2018-09-11
Assignee
Inventors
Cpc classification
G01F23/804
PHYSICS
International classification
G01F23/00
PHYSICS
Abstract
Described is a method and system for a level measurement. An echo curve is analyzed, and both the level and the moisture content of the stored material is determined therefrom. The level measuring instrument works in such an energy-saving manner that it is sufficient to supply the instrument with power using a 4 . . . 20 mA two-wire conductor loop that is also used to transmit at least some of the measured values.
Claims
1. A level measuring instrument for determining a level of a stored bulk material, comprising: a radio frequency unit generating a measurement signal; a signal processing unit determining the level of the stored bulk material from an echo curve of the measurement signal; and a temperature measuring device configured to acquire a temperature value to determine a temperature, the temperature measuring device being arranged in or on any one of i) a housing of the level measuring instrument or ii) a probe of the level measuring instrument; wherein the level measuring instrument determines, using the echo curve, a moisture content of the stored bulk material, the determining of the moisture content being based on an echo separation between echoes of the echo curve; and wherein the level measuring instrument improves, using the acquired temperature value, the accuracy with which the moisture content of the stored bulk material is deteimined.
2. The level measuring instrument according to claim 1, further comprising: a two-wire interface, wherein the level measuring instrument is supplied with power and outputs the measured level and moisture-content values, via the two-wire interface.
3. The level measuring instrument according to claim 2, further comprising: a data interface, wherein the level measuring instrument is supplied with power and outputs a first measured value, selected from the group of measured level and moisture-content values, via the two-wire interface; and wherein the level measuring instrument outputs a second measured value, selected from the group of measured level and moisture-content values, via the data interface.
4. The level measuring instrument according to claim 1, wherein the measurement signal is an FMCW signal.
5. The level measuring instrument according to claim 1, wherein the measurement signal is an electromagnetic pulse.
6. The level measuring instrument according to claim 1, wherein the level measuring instrument uses electromagnetic waves radiating into free space as the measurement signal.
7. The level measuring instrument according to claim 1, wherein the level measuring instrument uses guided microwaves as the measurement signal.
8. The level measuring instrument according to claim 7, comprising: a waveguide apparatus including a plurality of reflectors spaced apart from one another along a longitudinal extension direction of the waveguide apparatus, wherein the level measuring instrument determines a moisture profile from the echo curve and along the waveguide apparatus.
9. The level measuring instrument according claim 1, wherein the temperature measuring device is arranged as per any one of i) on and outside the housing of the level measuring device or ii) in or on the probe of the level measuring device.
10. The level measuring instrument according claim 1, wherein the temperature measuring device is arranged in or on the probe of the level measuring device.
11. The level measuring instrument according claim 10, wherein the probe includes a tensioning weight for tensioning at least one cable of the probe and wherein the temperature measuring device is arranged in or on the tensioning weight, the cable configured as a waveguide for guiding the measurement signal.
12. The level measuring instrument according to claim 10, wherein the determining the temperature is based on a length of the probe.
13. The level measuring instrument according claim 1, wherein the temperature measuring device is configured and arranged to acquire the temperature of the stored bulk material.
14. The level measuring instrument according to claim 1, wherein the determining the temperature is based on the determined level of the material.
15. The level measuring instrument according to claim 1, wherein the determining the moisture content is based on a length of a tension weight of the probe.
16. The level measuring instrument according to claim 1, wherein the stored bulk material is granular.
17. A method for determining, using a level measuring device, a level of a stored bulk material, comprising the steps of: generating a measurement signal; determining the level of the stored bulk material from an echo curve of the measurement signal; acquiring a temperature value to determine a temperature, the temperature value supplied by a temperature measuring device arranged in or on any one of i) a housing of the level measuring device or ii) a probe of the level measuring device; and using the temperature value, determining a moisture content of the stored bulk material from the echo curve, the determining of the moisture content being based on an echo separation between echoes of the echo curve.
18. The method according to claim 17, further comprising the step of: supplying an electrical power, via a 4 . . . 20 mA two-wire interface, to an instrument performing the method.
19. The method according to claim 18, further comprising the step of: outputting the measured level and moisture-content values, via the two-wire interface.
20. A program element, which, when executed on a processor, instructs the processor to perform determining steps of a method according to claim 17.
21. A non-transitory machine-readable medium on which a program element is stored which, when executed on a processor, instructs the processor to perform determining steps of a method according to claim 17.
Description
SHORT DESCRIPTION OF THE FIGURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
DETAILED DESCRIPTION OF EMBODIMENTS
(9) The depictions in the figures are schematic and not to scale.
(10) Where the same reference signs are used in different figures in the following description of the figures, they denote the same or similar elements. The same or similar elements may also be denoted by different reference signs, however.
(11)
(12) Level measuring instruments 105 that are supplied with power via a 4 . . . 20 mA current loop 109 in particular are commercially important. In this case, the level measuring instrument 105 comprises a suitable power supply 107, which in particular contains an energy storage unit and an energy control unit, and which controls the other components in the sensor in a suitable manner to ensure a stable measurement operation. The level value measured by the sensor can be provided externally in analogue form via the 4 . . . 20 mA interface 106.
(13) It is also possible to provide the measured value in digital form, for example using HART, Profibus, FF or Modbus.
(14) In addition, it is possible to measure the level using guided microwaves.
(15) On the other hand, dedicated moisture meters can be used to determine the moisture content of the medium 108 to be measured.
(16) The measurement converter unit 302 calculates a relative permittivity .sub.R from the transit times of the signal along the probe 306, which permittivity can be converted into a moisture value F by taking into account media properties, which must be set in advance. To a good approximation, a proportional characteristic can be assumed here:
F=c.Math..sub.R
where c is a constant that depends on the medium (and possibly the temperature) and is known in advance for the stored medium.
(17) The calculated moisture value can be provided externally at a suitable digital interface 304, for instance RS-232.
(18) In addition, the moister meter 302 usually comprises a further interface 305, which supplies the sensor unit 301 with power.
(19) These sensors are not intended to be used to measure level and moisture content simultaneously. Furthermore, moisture meters measure the transit time along the measuring probes 306 by means of direct time-measurement techniques, which can result in large measurement errors owing to the extremely short time periods. The accuracy can be improved by averaging a plurality of measurements, which in turn greatly increases the power consumption of the moisture meter 301 and consequently prevents implementation as a 4 . . . 20 mA two-wire device.
(20)
(21) The measuring instrument 401 has a radio frequency unit 101, a signal processing unit 106 and a modified power supply unit 402. In addition, the measuring instrument 401 has a moisture calculation unit 403.
(22) The measuring instrument 401 transmits a radio frequency signal 102 towards the medium 108 to be measured. Part of the microwave energy is reflected at the surface 104 of the medium 108 and arrives back at the measuring instrument 401 after an appropriate transit time.
(23) Another part of the microwave energy 404 penetrates the medium 108 and is not reflected until the lower limit 405 of the medium. The lower limit is often provided by the container base. The radio frequency unit 101 processes the received signals and can use known techniques to provide an echo curve 406 in digital or analogue form. In addition to the antenna echo 407 resulting from immediate reflections inside the antenna, the echo curve contains the level echo 408 originating from the reflection at the surface 104 and additionally the base echo 409 resulting from the reflection at the container base 405.
(24) The signal processing unit 106 can use known methods for calculating the distance d to the stored-material surface, on the basis of the echo curve 406. The calculated distance can be provided in analogue form at a 4 . . . 20 mA interface 109. Alternatively or additionally, the value can be provided via a digital interface.
(25) After calculating the distance d to the stored-material surface, the moisture calculation unit 403 uses the echo curve 406 and the distance d to the stored-material surface to calculate the moisture content of the medium 108. For this purpose, the material characteristic values can be preset as parameters in the moisture calculation unit 403. It should be mentioned here that the moisture calculation unit 403 may be provided as part of the signal processing unit or as a separate component.
(26) Various methods can be used to calculate the material moisture content F itself. One option is to analyse the amplitude A.sub.L of the stored-material echo 408, from which the moisture content can be deduced when material characteristic values are known. To a good approximation, the following holds:
(27)
where c is a constant that depends on the medium (and possibly the temperature) and is known in advance, A.sub.E is the maximum amplitude of the signal emitted by the level measuring instrument, and A.sub.L is the amplitude of the stored-material echo.
(28) Another option is to analyse the attenuation of the microwave signals 102 in the material 108, which can be calculated from the amplitude of the stored-material echo 408 and from the amplitude of the base echo 409. The moisture content of the medium can be deduced from the attenuation in a known manner using specific material characteristic values.
(29) The attenuation coefficient is defined by:
(30)
where .sub.0 is the wavelength of the signal used for the measurement .sub.R is the real part of the complex relative permittivity .sub.R is the imaginary part of the complex relative permittivity
(31) The attenuation D.sub.M in the medium can be calculated from measurements using the following equation:
(32)
where A.sub.B is the amplitude of the base echo A.sub.H is the maximum amplitude of the signal emitted by the level measuring instrument A.sub.L is the amplitude of the stored-material echo
(33) The distance d.sub.B to the container base, which is already known, and the current distance d to the stored material, can be used to calculate the attenuation coefficient using:
(34)
(35) Taking into account already known material-specific or negligibly small characteristic values for the imaginary part of the relative permittivity, the real part of the relative permittivity can be determined by transformation and can be used to directly deduce the moisture content of the medium. These non-linear relationships can be converted and solved in the instrument in particular using numerical approximation techniques.
(36) In a third variant, the moisture may also be calculated from the separation D.sub.M 411 of the stored-material echo 408 from the base echo 409 using the container height d.sub.S 412 and material-dependent characteristic values.
(37) The phase coefficient is defined by:
(38)
where .sub.0 is the wavelength of the signal used for the measurement .sub.R is the real part of the complex relative permittivity .sub.R is the imaginary part of the complex relative permittivity
(39) The phase rotation in the medium can be evaluated from measurements on the basis of the increase in the separation D.sub.M (411) between the stored-material echo and the base echo. The following holds:
(40)
where d.sub.B is the physical distance from the measuring instrument to the container base d is the physical distance from the measuring instrument to the stored-material surface
(41) Taking into account already known material-specific or negligibly small characteristic values for the imaginary part of the relative permittivity, the real part of the relative permittivity can be determined by transformation and can be used to directly deduce the moisture content of the medium. These non-linear relationships can be converted and solved in the instrument, in particular using numerical approximation techniques.
(42) It may also be possible to combine at least two of the methods mentioned above. For instance it may be advantageous particularly to evaluate within a single measurement both the attenuation of the signal within the medium and the phase rotation represented in the increase in the separation D.sub.M, and then to calculate from the above equations, using numerical techniques, the exact values for the real and imaginary parts of the relative permittivity. It may thereby be possible to measure the moisture in the material even more accurately.
(43) The calculated moisture value can be passed to the communications unit 402, which provides said value externally. For this purpose, the sensor may have a second analogue 4 . . . 20 mA interface 410. It may also be possible, however, to provide the characteristic value in analogue and/or digital form at the existing interface 109.
(44) It should be mentioned at this point that, in the context of the present invention, a moisture content or a moisture value or a moisture level may be at least one value selected from the group of measurable values comprising gravimetric moisture content, percentage of moisture by mass, percentage of dry matter by mass, volumetric moisture content and percentage of moisture by volume.
(45) The modified power supply unit 402 ensures that the actual measurement-data acquisition procedure is stable. Only a minimum amount of extra power needs to be supplied compared with existing instruments purely for level measurement, because the actual energy-intensive process of echo-curve acquisition in the radio frequency unit 101 must only be performed once per measurement cycle, as in a conventional level measuring instrument. Calculating the moisture characteristic values in the unit 403 may be implemented in combination with the signal processing 106 in the form of software algorithms in a processor that already exists anyway, and requires only a minimum of extra power.
(46) It may also be a special feature of the measuring instrument that the echo curve can be acquired in the radio frequency unit 101 in a particularly energy-saving manner by means of a sequential sampling technique. This results in a significant power saving compared with direct time-measurement techniques such as those that can be used in pure moisture meters, allowing the combined sensor to be designed as a two-wire measuring instrument. Further advantages of the sequential sampling technique also include an increased dynamic response, which also allows detection of very small echoes, and a higher measurement rate.
(47)
(48) The measuring instrument 501 can consist of the radio frequency unit 502 also present in other level measuring instruments, the signal processing unit 504 and the interface to a higher-level controller 506, which is typically implemented as a 4 . . . 20 mA interface. Furthermore, the measuring instrument 501 has a moisture calculation unit 503 and a power-supply and communications unit 505.
(49) A temperature measuring device 520 can also be provided. The temperature measuring device 520, also referred to below as a temperature sensor, can be located, for example, in or on the tensioning weight 204. Alternatively or additionally to this, a temperature measuring device 706, 707 can be arranged inside the measuring instrument 501, as shown in
(50) The temperature measured inside the sensor can be converted into an estimate of the temperature of the medium 108 using factory-measured characteristic values and taking into account the length L of the probe 202, which length may be factory-specified for example. The temperature measurement can be located particularly advantageously immediately beside the outlet point of the probe 202 in the measuring instrument 501. This structural design allows the thermal conductivity of the metal probe 202 to be used to indirectly measure the temperature of the medium 108. A constant heat flow is established inside the probe 202 over the measurement cycle concerned. The temperature of the medium can be directly deduced from the distance of the medium from the measuring instrument (equals the current level value) and the thermal conductivity of the metal in conjunction with the measured temperature change at the outlet of the probe.
(51) Further improvements are obtained when the cooling effect of the connection of the probe 202 to the sensor 501 is taken into account. If this connection is considered as a cooling body, then its cooling capacity can be ascertained in advance at the factory. Any effected changes in the heat dissipated by the cooling body can be taken into account in the calculation if the prevailing ambient temperature is measured by means of a second temperature sensor (not shown here) on the outer wall 501 of the sensor. Measuring the temperature difference that actually exists on the resultant cooling body allows calculation of the heat flow, from which the temperature of the medium can be directly deduced, again taking into account the thermal conductivity (Fourier's law).
(52) The temperature measuring device measures a temperature value, which can be used to improve the accuracy with which the moisture content is determined.
(53) The measured temperature values can significantly improve the determination of the moisture value on the basis of the echo curve acquired by the level measuring instrument.
(54) A rule for correcting the moisture content of the stored product as a function of the temperature can be hardcoded into the level measuring instrument for instance when the instrument is being manufactured, so that the relevant temperature compensation curves can be directly accessed during operation of the measuring instrument.
(55) Alternatively or additionally, an interface for an external temperature sensor, for example a PT 100, can be provided on the measuring instrument or on the tensioning weight.
(56) The temperature sensor can be designed to transmit to the electronics 502-505 of the measuring instrument the acquired data via a data-transmission and power-supply line assembly arranged in the waveguide 202, which is in the form of a cable for example.
(57) It can be provided that the measuring instrument determines the moisture content in two or more regions of the measuring probe that include tensioning weights 202, 204 by analysing different segments of the echo curve. A moisture curve in the form of a two-level or multi-level step function can be determined in this manner.
(58) For example, the region of the echo curve attributable to the region 521 of the measuring probe located in the stored material can be used as the first moisture measurement region. The region of the echo curve attributable to the length 522 of the tensioning weight 204 or of another reference body can be used as the second moisture measurement region.
(59) The moisture curve can be determined in a similar way also for level measuring instruments that perform non-contact measurements. The holes in a standpipe or reference measurement point(s) made in the container can be used as reflectors that can be identified in the echo curve.
(60) The measuring instrument 501 first detects an echo curve 507, which reproduces the reflection conditions along the waveguide 202. The echo curve 507 initially contains the echo 508 from the junction with the waveguide 202 and also the stored-material echo 509 generated by the stored-material surface 104. In the present example, the waveguide apparatus 202 has a tensioning weight 204, which is depicted by two echoes 510, 511 in the echo curve, the first echo identifying the start of the tensioning weight and the second echo identifying the end of the tensioning weight.
(61) A measurement cycle in the measuring instrument 501 may proceed in the same way as in the radar instrument 401 described above. The same techniques and approaches may also be used to actually determine the material moisture content.
(62) Furthermore, there are additional options for determining the moisture content of the material 108.
(63) In theory, the propagation speed of a microwave signal 512, 102 in a medium 108 is reduced according to the material properties (relative permittivity, granularity, compaction) and according to the moisture content of the material. In terms of measurements, this can be identified in the echo curve by the separation between two reflection points within the medium appearing larger in the echo curve. In the example shown in
(64) From the measured increase in the separation of these two echoes, it is possible to use the physical separation l.sub.S of the associated reflection points, which is known in advance, to deduce the current relative permittivity of the medium, which can be converted directly into a moisture value when the associated material characteristic values are known.
(65) The following holds:
(66)
where D.sub.S is the separation of the two echoes of the tensioning weight in the echo curve l.sub.S is the physical length of the tensioning weight
(67) Taking into account already known material-specific or negligibly small characteristic values for the imaginary part of the relative permittivity, the real part of the relative permittivity can be determined by transformation and can be used to directly deduce the moisture content of the medium according to the relationships already disclosed.
(68) It may also be a special feature of the measuring instrument 501 that the echo-curve can be acquired in the radio frequency unit 502 in a particularly energy-saving manner by means of a sequential sampling technique. This results in a significant power saving compared with direct time-measurement techniques such as those that can be used in pure moisture meters, allowing the combined sensor to be designed as a two-wire measuring instrument. Further advantages of the sequential sampling technique also include an increased dynamic response, which also allows detection of very small echoes, and a higher measurement rate.
(69) Since the stored material distances lie in the range of a few centimetres to several metres, and the propagation speed of electromagnetic waves even in a medium is close to the speed of light, the radio frequency signal transit times lie in the range of a few nanoseconds. In order to be able to measure these signals very accurately, a suitable approach is to expand by several orders of magnitude the voltage curve of the received electrical signal which represents the reflection conditions along the propagation direction of the electromagnetic wave.
(70) This is done by means of a sequential sampling technique in which the transmitted/received signal is sampled periodically at temporally equidistant intervals. If the sample time is continually offset with respect to the transmission time, when combined the individual samples recreate an image of the original signal, albeit now a time-expanded image. The defined offset of the sample time with respect to the transmission time is vital to obtaining a uniformly constant, error-free time expansion. The result of this technique is an echo curve (406, 507), which is advantageously sampled over a time period of a few milliseconds and stored in the memory of a processor.
(71) The embodiments of the measuring instrument presented so far allow an average moisture value to be determined, as can also be determined using other measuring instruments.
(72)
(73) The two lines may be positioned at a defined distance from one another by regularly arranged spacers 603. The spacers can be formed by any insulating materials. For example, plastics materials that have a high mechanical strength can be used.
(74) The measuring instrument acquires an echo curve 611 as in the above-mentioned examples in a known manner. The individual spacers each separately reflect some of the microwave energy, which is represented by echoes 607 in a correspondingly regular arrangement in the echo curve.
(75) The separation k.sub.1, k.sub.2, etc. of the respective echoes in the echo curve corresponds, up to the actual stored-material echo 617, to the physically present separation of the spacers 603, which is known in advance. Below the stored material level, i.e. at distances greater than the distance to the stored-material surface, the microwaves experience a reduction in the propagation speed, which depends, inter alia, on the moisture content of the medium in the segment through which the microwaves are passing. The physically constant separation k between the spacers 603, 604, 605, 606 covered by the stored material 108 is depicted in the echo curve by different measured distances K.sub.u, K.sub.v, K.sub.w 608, 609, 610.
(76) The moisture calculation unit 616 can determine from each of these distances, depicted having an increased length, a respective moisture value F(d) (612, 613, 614) of the material at the corresponding distance d from the measuring instrument. The procedure for evaluating the individual separations K.sub.i corresponds to the procedure described above for analysing the two echoes from a tensioning weight. The formulas described there apply analogously also to the case of two adjacently arranged discontinuities on the probe. The moisture value F calculated in each case can be assigned to the distance at the centre between the spacers concerned.
(77) Interpolation techniques can be used to determine from the calculated characteristic values 612, 613, 614 a complete moisture profile 615 of the medium in the container, and can be provided at the interface 506 of the sensor in analogue and/or digital form.
(78) This principle can also be applied to single conductors, coaxial conductors or hollow conductors by providing discontinuities at intervals along the coaxial conductor or hollow conductor.
(79) The determination of the moisture content of a medium using electromagnetic waves can be further improved by taking into account the temperature of the medium.
(80)
(81) The change in the relative permittivity for different media depending on the temperature is known in advance and can be obtained from the corresponding standard references for microwave measurement technology. The dependencies can be hardcoded into the instrument during manufacture, so that the temperature compensation curves can be directly accessed during operation.
(82) The measuring instrument 701 can be designed as a radar level indicator, which can determine a three-dimensional or at least two-dimensional moisture profile. To do this, the radar level indicator scans the surface of the stored material (bulk solid) and thereby acquires a series of echo curves, each echo curve corresponding to a different main emission direction of the radar level indicator antenna. From each echo curve, it is possible to determine the moisture content of the stored product in a specific region of the stored product (through which the respective main emission direction runs). Thus a moisture distribution, i.e. a 2D or 3D moisture profile of the stored product, is obtained from the different moisture contents determined in this manner.
(83) Further improvements result when using a non-contact temperature measuring unit 707, as used in a further apparatus 702. The temperature measuring unit 707, produced for example as an infrared thermometer, determines the temperature at the surface 709 of the medium to be measured in a non-contact manner, and forwards this temperature to the moisture calculation unit 704, which can now calculate the moisture content of the medium 104 with even greater accuracy.
(84) When using guided microwaves, there are further options for direct, contacting measurement of the temperature of the medium 104. The apparatus 703 uses for this purpose one or more temperature sensors 708 installed over the length of the waveguide apparatus 710 (which may be the measuring apparatus 202 of
(85) The individual temperature sensors can be installed directly in the waveguide apparatus 710, for example directly during manufacture of the corresponding cable 710 or when attaching corresponding tensioning weights 204. In particular, the temperature measuring device can be attached directly in or on the tensioning weight 204. It may also be possible to position a temperature measuring device, which is arranged in parallel with the waveguide apparatus 202, 710, that allows at least one temperature of the medium 104 to be measured.
(86)
(87) In addition, it should be mentioned that the terms comprising and having do not exclude any other elements or steps, and a or an does not rule out a plurality. It should also be pointed out that features or steps that have been described with reference to one of the above embodiments can also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims shall not be deemed to have a limiting effect.