SENSOR ASSEMBLY WITH ALIGNMENT DEVICE

Abstract

A sensor arrangement is provided for level measurement or limit level measurement of a filling material or a bulk material in a container, the sensor arrangement including: a sensor with an antenna; and a sensor housing having an alignment device including a first portion and a second portion configured to receive the antenna, the first portion and the second portion being configured to be rotatable relative to each other, in which the alignment device is configured to change a radiation direction of a measurement signal of the sensor by rotating the first section and/or the second section. A sensor housing including an alignment device is also provided.

Claims

1-25. (canceled)

26. A sensor arrangement for level measurement or limit level measurement of a filling material or a bulk material in a container, the sensor arrangement comprising: a sensor with an antenna; and a sensor housing having an alignment device comprising a first portion and a second portion configured to receive the antenna, the first portion and the second portion being configured to be rotatable relative to each other, wherein the alignment device is configured to change a radiation direction of a measurement signal of the sensor by rotating the first section and/or the second section.

27. The sensor arrangement according to claim 26, wherein the first portion includes a first cavity, and wherein the second portion includes a second cavity in which the antenna is disposed.

28. The sensor arrangement according to claim 26, wherein the antenna is disposed off-center or centered in the second portion of the sensor housing.

29. The sensor arrangement according to claim 26, further comprising a polarization device configured to change a polarization of the measurement signal by rotating the first section and/or the second section.

30. The sensor arrangement according to claim 26, wherein the sensor housing is completely closed and/or cannot be opened non-destructively.

31. The sensor arrangement according to claim 26, wherein the sensor is configured as a stand-alone radar sensor.

32. The sensor arrangement according to claim 26, further comprising an attachment device disposed between the first portion and the container and configured to attach the sensor assembly to the container via the first portion.

33. The sensor arrangement according to claim 26, further comprising an absorber device formed of an absorber material and disposed in the first portion of the sensor housing.

34. The sensor arrangement according to claim 26, wherein the first portion and the second portion are each in the form of an obliquely cut hollow cylinder and are configured to integrally and cylindrically form the sensor housing, and wherein the sensor housing of the alignment device includes an inclined surface disposed between the first portion and the second portion and is configured such that the first portion and the second portion are rotatable relative to each other via the inclined surface.

35. The sensor arrangement according to claim 27, wherein the antenna of the sensor is configured to protrude into the first cavity.

36. The sensor arrangement according to claim 26, wherein the sensor housing comprises a third portion having a third cavity disposed between the first portion and the second portion and is configured to be rotatable relative to at least one of the first portion and the second portion.

37. The sensor arrangement according to claim 36, wherein the first portion and the third portion are each formed as an obliquely truncated hollow cylinder, and the second portion is formed as a hollow cylinder, wherein the first portion, the second portion, and the third portion are configured to form the sensor housing integrally and cylindrically, and wherein the sensor housing has an inclined surface disposed between the first portion and the third portion and is configured such that the first portion and the third portion are rotatable relative to each other via the inclined surface, and a straight surface disposed between the second portion and the third portion.

38. The sensor arrangement according to claim 36, wherein the antenna of the sensor is formed in the second cavity so as to protrude into the first cavity and/or the third cavity.

39. The sensor arrangement according to claim 36, wherein the antenna is configured to be disposed at a highest position by rotating the second portion relative to the third portion and rotating the third portion relative to the first portion.

40. The sensor arrangement according to claim 36, wherein the second portion is formed separably from the first portion and the third portion, and wherein the sensor housing comprises a first housing unit formed by the first portion and the third portion, and a second housing unit formed by the second portion.

41. The sensor arrangement according to claim 40, further comprising a fastening means disposed between the first housing unit and the second housing unit and configured to connect the first housing unit and the second housing unit.

42. The sensor arrangement according to claim 26, wherein the first portion is in the form of a bracket and the second portion of the sensor housing is in the form of a spherical segment.

43. The sensor arrangement according to claim 26, further comprising a sealing member configured to seal the sensor housing.

44. The sensor arrangement according to claim 26, wherein the first portion is in the form of a bracket and the second portion is in the form of a flattened spherical segment.

45. The sensor arrangement according to claim 26, wherein the first portion is in the form of a support device and the second portion is in the form of a hollow cylinder, and wherein the second portion is connected to the first portion by a connecting means.

46. The sensor arrangement according to claim 45, further comprising a third portion having a shape of a rubber sleeve and disposed between the first portion and the second portion.

47. The sensor arrangement according to claim 36, further comprising a filter disposed at the first portion and/or the third portion of the sensor housing.

48. A sensor housing comprising an alignment device configured to mount and to align a sensor arrangement according to claim 26 on a container for level or point level measurement of a product or bulk material in the container.

49. The sensor arrangement according to claim 26, the sensor arrangement being configured to measure a level or a limit of a filling material or a bulk material in a container.

Description

SHORT DESCRIPTION OF THE FIGURES

[0084] FIG. 1a shows a schematic diagram of a measurement setup of a sensor arrangement according to an embodiment.

[0085] FIG. 1b shows a schematic diagram of a measurement setup of a sensor arrangement according to an embodiment.

[0086] FIG. 2 shows a schematic side view of a sensor housing of a sensor arrangement according to an embodiment.

[0087] FIG. 3 shows a schematic top view of a sensor arrangement according to an embodiment.

[0088] FIG. 4a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0089] FIG. 4b shows a schematic representation of a sensor arrangement according to a further embodiment.

[0090] FIG. 4c shows a schematic representation of a sensor arrangement according to a further embodiment.

[0091] FIG. 5a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0092] FIG. 5b shows a schematic representation of a sensor arrangement according to a further embodiment.

[0093] FIG. 5c shows a schematic representation of a sensor arrangement according to a further embodiment.

[0094] FIG. 6a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0095] FIG. 6b shows a schematic representation of a sensor arrangement according to a further embodiment.

[0096] FIG. 7a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0097] FIG. 7b shows a schematic representation of a sensor arrangement according to a further embodiment.

[0098] FIG. 8a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0099] FIG. 8b shows a schematic diagram of a sensor arrangement according to an embodiment.

[0100] FIG. 9a shows a schematic representation of a sensor arrangement according to an embodiment.

[0101] FIG. 9a shows a schematic representation of a sensor arrangement according to a further embodiment.

[0102] FIG. 10a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0103] FIG. 10b shows a schematic representation of a sensor arrangement according to a further embodiment.

[0104] FIG. 11a shows a schematic diagram of a sensor arrangement according to an embodiment.

[0105] FIG. 11b shows a schematic representation of a sensor arrangement according to a further embodiment.

DETAILED DESCRIPTION OF EXAMPLARY EMBODIMENTS

[0106] FIG. 1a schematically shows a measurement setup of a sensor arrangement 10 according to an embodiment. The sensor arrangement 10, which comprises a sensor, is mounted or installed outside a container 20 or on the sloping container roof and is arranged for level or limit level measurement of a filling material or a bulk material 25 in the container. The sensor arrangement 10 is adapted to emit and receive a measurement signal 30 or a measurement beam through the container roof.

[0107] The container 20 with the sloped container roof may be made of a plastic or a GRP. For example, the container in FIG. 1 may be a GRP silo that has a cone-shaped container lid when used in an animal feed system. Alternatively, FIG. 1b shows a GRP tank as the container 20 with a round container lid.

[0108] Importantly, when the sensor assembly is mounted on the sloped container roof, the sensor may be oriented substantially vertically downward or toward the product or bulk material 25 for reliable measurement.

[0109] FIG. 2 shows a sensor housing 100 having an alignment device 101 that includes the sensor arrangement 10. The alignment device 101 of the sensor housing 100 includes a first portion 110, a second portion 120, and a third portion 130.

[0110] The first section 110 has a first cavity 115 and is arranged as a lower part of the sensor housing. The second section 120 has a second cavity 125 and is arranged as an upper part of the sensor housing. The third section 130 has a third cavity 135 and is disposed between the first section 110 and the second section 120.

[0111] The first section 110, the second section 120, and the third section 130 are connected and adapted to form the sensor housing 100 integrally and cylindrically. In this regard, the second section 120 is formed as a hollow cylinder and the first section 110 and the third section 130 are each formed as an obliquely cut hollow cylinder. The sensor housing 100 may be completely closed and/or may be non-destructively openable.

[0112] The third section 130 is configured to be rotatable relative to the first section 110 and/or the second section 120, respectively. In other words, the housing portions, namely the first section 110, the second section 120 and the third section 130, are rotatable relative to each other. Thus, the sensor housing 100 has two axes of rotation or two surfaces of rotation, which are an oblique surface disposed between the first section 110 and the third section 130, and a straight surface disposed between the second section 120 and the third section 130.

[0113] The cavities 115, 125, 135 of the sensor housing may form a common cavity or each may be formed as a separate, closed cavity. The rotation surfaces of the sensor housing 110 may each be provided by the cut surfaces or edges at the junctions between the first and third sections 110, 130 and between the second and third sections 120, 130. In the case where the common cavity is formed, the rotation surfaces may be virtual rotation surfaces.

[0114] A sealing member 300 may be provided at the junctions between the first, second, and third sections 110, 120, 130 to seal the sensor housing 100.

[0115] Air or vacuum may be present in the cavities. Further, an absorber device 500 comprising an absorbent material may be provided, for example, in the first cavity 115 and/or in the third cavity 135 or on the inner walls of the first section 110 and the third section 130. The absorber device 500 may be arranged to protect the measurement signal from deflection or attenuation as it passes through the alignment device, so that the interference effects on the measurement results can be eliminated or at least minimized.

[0116] The sensor of the sensor arrangement 10 may include an antenna 200, which may be, for example, a horn antenna, array antenna, or lens antenna, or a parabolic antenna.

[0117] As shown in FIGS. 4a-c, the antenna 200 is received in the sensor housing 100 through the second portion 120 or is secured or disposed in the upper portion of the second cavity 125.

[0118] Furthermore, FIG. 3 shows in a top view of the sensor arrangement 10 that the antenna 200 may be arranged off-center in the sensor housing 100.

[0119] The sensor arrangement 10 in FIGS. 4a-c further comprises electronics 220 including a circuit board connected to the antenna 200 and mounted and secured in the upper portion of the sensor housing or the second portion 120.

[0120] Alternatively, the antenna 200 may be fixed centrally in the sensor housing 100 and/or in the cavity 125 of the second section 120, as shown in FIGS. 6a-b. The antenna 200 is configured to protrude into the first cavity 115 and/or the third cavity 135.

[0121] The sensor arrangement 10 further comprises a mounting device 400 provided at the lower side of the sensor housing 100. When the sensor arrangement is mounted to the sloped roof of the container 20, the mounting device 400 is disposed between the first section 110 and the container 20 and is configured to mount the sensor arrangement 10 over the first section 100. The mounting may be performed by an adhesive mounting via an adhesive surface, i.e., the mounting device 400 may be an adhesive, such as an adhesive tape. Thus, an adhesive surface may be provided between the lower side of the sensor housing 100 or the first section 110 and the container roof. Alternatively or additionally, the mounting device 400 may be a mounting plate.

[0122] When the sensor arrangement 10 with the off-center antenna 200 is attached to the container roof, the alignment device 101 may be arranged to change the radiation direction of the measurement signal 30 of the sensor by rotating the first section 110 and/or the second section 120 and/or the third section 130.

[0123] FIG. 4a shows that the sensor housing 100 is still cylindrical, for example, without rotating the sections 110, 120, 130, and the antenna is located on the left side of the sensor housing 100 and oriented in a vertical direction. In FIG. 4b, after being placed on the sloped container roof, the third section 120 may be rotated, for example 90 degrees, so that the cylindrical second section 120 may be horizontal or an acute angle may be formed between the vertical orientation of the antenna 200 and the container roof. Furthermore, the second section may be rotated, for example, 90 degrees, so that the antenna 200 may be positioned in the center of the second section, as shown in FIG. 4b. Thus, the position of the antenna 200 in the sensor housing 100 can be changed by rotating the third section 130 and/or the second section 120. Compared to FIG. 4b, the container 20 in FIG. 4c has a more inclined container roof on which the sensor arrangement 10 is mounted by means of the mounting device 400. The third section 130 may further be rotated, for example 180 degrees, so that the second section 120 may be disposed horizontally or a smaller acute angle may be formed between the orientation of the vertical alignment of the antenna 200 and the container roof. The second section 120 may further be rotated, for example by 180 degrees, such that the antenna 200 may be positioned on the right side as shown in the side view, as shown in FIG. 4c, or symmetrically with respect to the position of the antenna where the antenna is on the left side before rotation.

[0124] By rotating the second section 120 and/or rotating the third section 130 during assembly by means of the first section 110, the antenna 200 may be formed so that the antenna 200 may be located at a highest position on the container roof. The measurement signal may be emitted at the highest position from the measurement sensor or from the antenna through the container roof and may be emitted perpendicular to the surface of the filling material or in the direction of the filling material.

[0125] The sensor arrangement 10 can advantageously allow the sensor to be easily mounted on a process vessel having a sloped, for example, conical or round or lump-shaped vessel lid, while providing a reliable measurement.

[0126] As shown in FIGS. 6a-b, a polarization device may additionally be provided in the sensor arrangement 10 or in the sensor housing 30, for example in the first section 110, which is arranged to change the polarization of the measurement signal 30 by rotating the first section 110, the second section 120 or the third section 130. Alternatively or additionally, the polarization device may be provided between the first section and the second section or between the first section and the container roof. The provision of the polarization device can facilitate and significantly optimize the change of alignment of the antenna 200 or of the measuring signal 30 in the direction of the filling material or bulk material, in particular if the antenna 200 is arranged centrally in the second section 200 and thus the position or the height of the antenna cannot be changed by rotating the second section and/or if the container roof has a particularly inclined design and an additional adjustment of the radiation direction of the measuring signal is necessary, for example as a fine adjustment.

[0127] As an alternative to the three-part sensor housing of the sensor arrangement 10 in FIGS. 4a-c and FIGS. 6a-b, a sensor arrangement 10 is shown in FIGS. 5a-c, which comprises a two-part sensor housing 100 with an alignment device having two sections directly connected to each other, namely a first section 110 as a lower part and a second section 120 as an upper part. Thus, the sensor housing 100 of the sensor arrangement 10 may dispense with a third section as an intermediate part. Thus, the sensor arrangement having the two-part sections 110, 120 can have a compact structure.

[0128] The sensor assembly 10 in FIGS. 5a-c has a single axis or surface of rotation at the junction between the first section 110 and the second section 120. The first section 110 and the second section 120 each have the shape of an obliquely truncated hollow cylinder, and are configured to form the sensor housing 100 of the integrally and cylindrically. The rotating surface is an inclined surface disposed between the first section and the second section. Via the inclined surface, the first section and the second section can be rotated relative to each other so that the sensor housing 100 can no longer be cylindrical in shape.

[0129] The alignment device of the sensor arrangement is thus arranged to change the radiation direction of the measurement signal 30 of the sensor by the first and second sections, which can be rotated relative to each other. The antenna 200 may also be received or disposed off-center in the second section. Furthermore, the antenna 200 is configured to protrude into the first cavity. In FIG. 5a, the sensor housing 100 is cylindrical in shape and the antenna 200 is disposed within the sensor housing, for example, to the left of center. When mounting the sensor arrangement on the sloped container roof, the second section 120 may be rotated relative to the first section 110 by means of the alignment device to such an extent that the antenna may be arranged centrally in a side view, as shown in FIG. 5b, or may be arranged right of center in another side view, as shown in FIG. 5c. It may be an advantage that by arranging the antenna 200 off-center and rotating the second section, the antenna 200 may be attached to the shorter part of the housing part of the sensor housing.

[0130] FIGS. 7a-b show a sensor arrangement according to an alternative embodiment to the sensor arrangement in FIGS. 4a-c. The sensor arrangement has a sensor housing 100a that is not formed in one piece, but has two separable housing units, namely a first housing unit and a second housing unit. The first housing unit is formed by a first section 110a having a first cavity 115a and a third section 130a having a third cavity 135a and may be in the form of a hollow cylinder, while the second housing unit is formed by the second section 120a as a separate hollow cylindrical housing unit.

[0131] A second fastening device 400a is provided between the first housing unit and the second housing unit, and is adapted to connect the first housing unit and the second housing unit. For example, the second housing unit may be bonded to the first housing unit.

[0132] A sensor or a radar sensor including the antenna 200 and the circuit board 220 is housed or disposed in the second housing unit or the second section 120a. Therefore, the closed housing unit with the sensor disposed therein may form a self-sufficient measurement sensor.

[0133] In addition, the first housing unit may be designed as a separate alignment device or adapter for mounting and aligning the measurement sensor. The separately designed second housing unit can result in the sensor being easily replaceable and the second housing unit can be used as an adapter universal for sensors of different types.

[0134] Further, the first cavity 115a and the third cavity 135a may form a common cavity as in FIG. 7a and the alignment device may thus have a virtual rotating surface. Alternatively, the first cavity 115a and the third cavity 135a may each have their own closed cavity as in FIG. 7b.

[0135] A filter 600 or pressure equalization filter may be provided in the first cavity 115a and/or the third cavity 135a of the first housing unit as an alternative or in addition to the absorber device to equalize air pressure inside and outside the housing unit. If the first cavity 115a and the third cavity 135a form a common cavity, as shown in FIG. 7a, a filter may be provided. If the first cavity 115a and the third cavity 135a each form their own closed cavity, as shown in FIG. 7b, the filter may be provided in the respective closed cavity.

[0136] FIGS. 8a-b show a sensor arrangement according to another embodiment. The sensor arrangement includes a sensor 100 having an antenna 200 and electronics or a circuit board 220, and a sensor housing 100b having an alignment device with a first section 110b in the form of a bracket and a second section 120b having the form of a hollow sphere or spherical segment. The hollow sphere segment of the second section 120b may be an articulating socket.

[0137] As another embodiment to the sensor arrangement in FIGS. 8a-b, the sensor arrangement in FIGS. 9a-b and FIGS. 10a-b includes a sensor housing 100b having a second portion 120b in the form of a flattened spherical segment.

[0138] The first section 110b may alternatively be in the form of a hollow cylinder and have a first cavity 115b. The second section 120b of the alignment device or sensor housing 100b includes a first cavity 100b in which the sensor or antenna 200 and the circuit board 220 are received or disposed. The first portion 110b and the second portion 110b may be connected to each other and rotatable relative to each other, for example, by means of a threaded connection or a snap-on connection. In other words, the sensor may be clamped or arranged in the spherical second section 120b like a ball to the first section 110b as a mount.

[0139] A sealing member 300b may be provided at the joint and adapted to seal the sensor housing 100b.

[0140] An attachment device 400, such as an adhesive tape, may be provided between the first portion 100b and the container 20 when the sensor arrangement 10 is mounted, and may be configured to attach the sensor arrangement 10 to the container 20 over the first portion 110b. By adhesive mounting, the sensor arrangement 10 can be easily attached to a container roof, in particular a sloped container roof as shown in FIG. 8a, FIG. 9a-b or FIG. 10a-b, such that the first section 110b can be positioned below the second section 120b and the measurement signal can be radiated through the sensor housing 100b, the lower side of the first section 110b and the container wall. By rotating the first section 110b and/or the second section 120b, the sensor arrangement 10 may be provided outside of the container or in the immediate vicinity of the container as shown in FIG. 8b by means of the mounting device 400 such that the first section 110b may be disposed above the second section 120b and the measurement signal may be radiated through the sensor housing 100b and the container wall but not through the first section 110b. Thus, the sensor arrangement may be installed with any freedom. For example, the sensor can thus be rotated 360 degrees and oriented freely.

[0141] FIG. 9a and FIG. 9b show that the sensor arrangement 10 may further comprise a beam deflecting device 700, for example a lens and provided in the lower part of the second section 120b and arranged to deflect the measurement signal in the direction of the filling material in the container. Therefore, providing the beam deflecting means 700 may serve to change the direction of radiation of the measurement signal of the sensor in addition to rotating the first section and/or the second section by means of the alignment device.

[0142] Additionally, a filter 600 or pressure equalization filter and/or absorber device 500 may be provided in the first cavity 115b of the first section 110b.

[0143] For example, the antenna 200 may be centered, as shown in FIGS. 9a-b, or off-centered, as shown in FIGS. 10a-b, in the third section 120b. By arranging the antenna 200 off-center, the position of the antenna 200, for example from the left side in FIG. 10a to the right side in FIG. 10b, can be changed by rotating the second section 120b with respect to the first section 110b, and the radiation direction of the measurement signal can still be changed.

[0144] In FIGS. 11a-b, a sensor arrangement 10 is shown according to an alternative embodiment. The sensor arrangement 10 comprises a sensor housing 100c with an alignment device having a first section 110c in the form of a support device, a second section 120c in the form of a hollow cylinder, and a third section 130c in the form of a rubber sleeve. The second section 120c is connected to the first section 110c by a connecting means 118, for example a screw connection. The first section 110c may thus be formed as a base or a mounting bracket.

[0145] The rubber sleeve 130c is provided between the first section and the section and is adapted to close or form as a closed cavity the space between the sensor in second section 120c and the support device of first section 110c, to protect the cavity from entry of foreign particles from the environment. Thus, the sensor arrangement 10 can be used for outdoor process vessels in a long-term and reliable manner.

[0146] Supplementally, it should be noted that “comprising” or “having” does not exclude other elements, and “a” or “an” does not exclude a plurality. It should further be noted that features described with reference to any of the above embodiments may also be used in combination with other features of other embodiments described above. Reference signs in the claims are not to be regarded as a limitation.