GB2527840A - Improvements in level monitors for substances within vessels - Google Patents

Abstract

A level sensor transmitter and monitor for substances within vessels or containers is disclosed, wherein the readings made by liquid or flowing material level sensors are transmitted via dedicated connections, Internet or Wi-Fi methods to hand held, smartphone, or other compatible devices to enable the user to monitor level changes. A dedicated smartphone app may be provided. The users may remotely provide instructions for actions to the sensor / receiver to instigate physical functions or actions resulting in a working process taking place. The user may also remotely instruct an action to the container, such as to open a valve to release or add some material or fluid to the container.

Description

IMPROVEMENTS IN LEVEL MONITORS FOR SUBSTANCES WITHIN VESSELS

Field of the Invention

The present invention relates to the measuring and monitoring of levels of substances housed within storage vessels, using radar and ultrasonic devices and sensors, in relation to smartphones and other computer or intelligent receiving and viewing devices.

Background

The use of storage vessels within commercial industry to house types of material including liquids and semi solids is known and has been practiced for many years. These detect the level of substances that flow, including liquids, slurries, granular materials, and powders. Fluids and fluidized solids flow to become essentially level in their containers (or other physical boundaries) because of gravity whereas most bulk solids pile at an angle of repose to a peak. The substance to be measured can be inside a container or can be in its natural form (e.g., a river or a lake). The level measurement can be either continuous or point values. Continuous level sensors measure level within a specified range and determine the exact amount of substance in a certain place, while point-level sensors only indicate whether the substance is above or below the sensing point.

Generally the latter detect levels that are excessively high or low. There are many physical and application variables that affect the selection of the optimal level monitoring method for industrial and commercial processes. The selection criteria include the physical: phase (liquid, solid or slurry), temperature, pressure or vacuum, chemistry, dielectric constant of medium, density (specific gravity) of medium, agitation (action), acoustical or electrical noise, vibration, mechanical shock, tank or bin size and shape. Also important are the application constraints: price, accuracy, appearance, response rate, ease of calibration or programming, physical size and mounting of the instrument, monitoring or control of continuous or discrete (point) levels. In short, level sensors are one of the very important sensors and play very important role in variety of consumer/industrial applications.

As with other type of sensors, level sensors are available or can be designed using variety of sensing principles. Selection of an appropriate type of sensor suiting to the application requirement is very important.

Radar sensors are ideal for use in moist, vaporous, and dusty environments as well as in applications in which temperatures and pressures vary. Microwaves (also frequently described as RADAR), will, penetrate temperature and vapor layers that may cause problems for other techniques, such as ultrasonic.

Microwaves are electromagnetic energy and therefore do not require air molecules to transmit the energy making them useful in vacuums.

Microwaves/Radar, as electromagnetic energy, are reflected by objects with high conductive properties, like metal and conductive water. Alternately, they are absorbed in various degrees by low dielectric' or insulating mediums such as plastics, glass, paper, many powders and food stuffs and other solids.

Radar sensors are executed' in a wide variety of techniques. Two basic signal processing techniques are applied, each offering its own advantages: Pulsed or Time-Domain Reflectometry (TDR) which is a measurement of time of flight divided by the speed of light, similar to ultrasonic level sensors, and Doppler systems employing FMCW techniques. Just as with ultrasonic level sensors, microwave sensors are executed at various frequencies, from 1 0Hz to 30 0Hz.

Generally, the higher the frequency, the more accurate, and the more costly.

Microwave is executed non-contact technique or guided. The first is done by monitoring a microwave signal that is transmitted through free space (including vacuum) and reflected back, or can be executed as a "radar on a wire" technique, generally known as Guided Wave Radar or Guided Microwave Radar. In the latter technique, performance generally improves in powders and low dielectric media that are not good reflectors of electromagnetic energy transmitted through a void (as in non-contact microwave sensors). But with the guided technique the same mechanical constraints exist that cause problems for the capacitance (RF) techniques mentioned previously by having a probe in the vessel.

Non-contact based radar sensors are able to see through low conductivity microwave-transparent' (non-conductive) glass/plastic windows or vessel walls through which the microwave beam can be passed and measure a microwave reflective' (conductive) liquid inside (in the same way as to use a plastic bowl in a microwave oven). They are also largely unaffected by high temperature, pressure, vacuum or vibration. As these sensors do not require physical contact with the process material, so the transmitter /receiver can be mounted a safe distance above/from the process, even with an antenna extension of several metres to reduce temperature, yet still respond to the changes in level or distance changes e.g. they are ideal for measurement of molten metal products at over 1200°C.

Radar transmitters also offer the same key advantage of ultrasonics: the presence of a microprocessor to process the signal, provide numerous monitoring, controls, communications, setup and diagnostic capabilities and are independent of changing density, viscosity and electrical properties.

Additionally, they solve some of the application limitations of ultrasonics: operation in high pressure and vacuum, high temperatures, dust, temperature and vapor layers. Guided Wave Radars can measure in narrow confined spaces very successfully, as the guide element ensures correct transition to and from the measured liquid. Applications such as inside stilling tubes or external bridles or cages, offer an excellent alternative to float or displacement devices, as they remove any moving parts or linkages and are unaffected by density changes or build up.

They are also excellent with very low micrOwave reflectivity products like liquid gasses (LNG, LPG, Ammonia) which are stored at low temperatures/high pressures, although care needs to be taken on sealing arrangements and hazardous area approvals. On bulk solids and powders, GWR offers a great alternative to radar or ultrasonic sensors, but some care needs to be taken over cable wear and roof loading by the product movement/flow.

One perceived major disadvantage of microwave or radar techniques for level monitoring is the relatively high price of such sensors and complex set up.

However, price has reduced significantly over the last few years, to match those of longer range ultrasonics, with simplified set up of both techniques also improving ease of use. Ultrasonic level sensors are used for non-contact level sensing of highly viscous liquids, as well as bulk solids.

They are also widely used in water treatment applications for pump control and open channel flow measurement. The sensors emit high frequency (20 kHz to kRz) acoustic waves that are reflected back to and detected by the emitting transducer.

Ultrasonic level sensors are also affected by the changing speed of sound due to moisture, temperature, and pressures. Correction factors can be applied to the level measurement to improve the accuracy of measurement. Turbulence, foam, steam, chemical mists (vapors), and changes in the concentration of the process material also affect the ultrasonic sensor's response. Turbulence and foam prevent the sound wave from being properly reflected to the sensor; steam and chemical mists and vapors distort or absorb the sound wave; and variations in concentration cause changes in the amount of energy in the sound wave that is reflected back to the sensor. Stilling wells and wave guides are used to prevent errors caused by these factors. 4.

Proper mounting of the transducer is required to ensure best response to reflected sound.

In addition, the hopper, bin, or tank should be relatively free of obstacles such as weidments, brackets, or ladders to minimise false returns and the resulting erroneous response.

It can be stated that most modern systems have sufficiently "intelligent" echo processing to make engineering changes largely unnecessary except where an intrusion blocks the "line of sight" of the transducer to the target. Since the ultrasonic transducer is used both for transmitting and receiving the acoustic energy, it is subject to a period of mechanical vibration known as "ringing". This vibration must attenuate (stop) before the echoed signal can be processed. The net result is a distance from the face of the transducer that is blind and cannot detect an object. It is known as the "blanking zone", typically 150mm -im, depending on the range of the transducer.

The requirement for electronic signal processing circuitry can be used to make the ultrasonic sensor an intelligent device. Ultrasonic sensors can be designed to provide point level control, continuous monitoring or both. Due to the presence of a microprocessor and relatively low power consumption, there is also capability for serial communication from to other computing devices making this a good technique for adjusting calibration and filtering of the sensor signal, remote wireless monitoring or plant network communications. The ultrasonic sensor enjoys wide popularity due to the powerful mix of low price and high functionality.

Some restrictions remain within the use of, these types of level monitors within various environments, these include current monitoring availabilities.

A user can have the measurement broadcast of relayed to a screen normally housed within a close proximity of the reading device itself. However, the distance of this proximity may be several hundred metres or more in a nearby office or even to remotely housed terminals outside of the placement building of the sender unit.

This provides the ability for the user to view content levels of various vessels when remote but they must be within a range that is depicted by the system therein. With the advent of smart phone and tablet, pc technology in combination with localised Wi-Fi or long distance telecommunications and the internet, it is possible to deliver full viewed updates of tank or vessel container levels from and to any location and country.

The present invention therefore discloses a method wherein known liquid or flowing materials that are housed in vessels, may be monitored using current radar, ultrasonic or related systems, that are able to forward viewable updates of level status, to a user in a remote location via a dedicated delivery system or general Internet availability, to a mobile smart phone, PC or tablet, using known or emerging technologies. The ability and means of measuring between a fixed and moving point at any given moment in time, using known or emerging radar technology and/or ultrasonic technology to present an immediate measurement via telemetry and/or Wi-Fi which would be converted to a volume or distance of the users choosing via smart phone application and/or tablet.

Summary of the invention

According to the present invention there is provided a device that is inserted or housed within a vessel or container, within the container is housed an industrial process, commercial bi-product or dedicated supply flowing material. The device is a sensor that is able to examine and monitor the depth or content level of the material therein.

This sensor may have extensions that pass within the surface of the liquid or flowing material or that alternatively rely on transmitted beams of microwave, radar or other variants to examine the surface level.

As the level of the liquid or flowing material reduces or increases the level monitors or sensors are able to view this change and react to the slightest of minimal reductions or increased levels therein.

The data gathered may then be transmitted or sent to a data receiver outside of the immediate area of the housing of the device or sensor. The data transmitter is of suitable technology to perform the task of providing a link to its collective portal housed to the device or sensor itself Data transmission would be articulate and precise, proving the exacting nature of visible information that is already known in terminal remote displays, such as pc screens or similar dedicated methology. Delivery would be accompanied by a data distribution method, this would include at Least one website of public or none public nature to enable the transmitted information to be collected and provided to the internet for private visual examination, interrogation, exploitation and feedback.

The website or Internet data centre would provide access to its information via an app which would correspond to its working capabilities. The app would be downloaded to any known or emerging hand held or other device, to include smart mobile telephones, pc tablets, for example, using a wide area WAN or local area LAN internet based network. Developing the apps for mobile devices will require considering the constraints and features of these devices. Mobile devices run on battery and have less powerful processors than personal computers and also have more features such as location detection and cameras. Development would also have to consider a lengthy array of screen sizes, hardware specifications and configurations because of intense competition in mobile software and changes within each of the platforms.

Although the known focus for monitoring of commercial or industrial vessels is possibly the management members of a company or commercial environment, it may be required that general staff or employees will be allocated the responsibility to examine and monitor tank or vessel levels daily from remote or onsite locations, therefore the use of known system adaption methods such as MAM (Mobile Application Management) should be considered to assist users to adapt their phones to onsite or system related use more easily.

This use of monitoring the sensors findings from within the vessel or container from a smart phone device may also suggest the ability to interrogate that received information or possibly control some elements in a return of information from the user to the sensor or device, providing or not providing an action.

The use of Wi-Fi would also lend itself to general communication from the user's terminal or smart phone to the transmitting device on a wider area. The combination of computer device or smart phone and interface controller is called a station.

All stations share a single radio frequency communication channel.

Transmissions on this channel are received by all stations within range. The hardware does not signal the user that the transmission was delivered and is therefore called a best-effort delivery mechanism. A carrier wave is used to transmit the data in packets, referred to as "Ethernet frames".

Each station is constantly tuned in on the radio frequency communication channel to pick up available transmissions. Therefore muftiple users can view information transmitted via the sensor device within the Wi-Fi range onsite.

The use of smart phones or other tablet or hand held devices from outside the sensor device location is possible. The user would open a corresponding app installed to their hand held device and this would link via the internet using localised Wi-Fi or any other dedicate commercial or private internet connection.

The app would then talk to the data receiver or website to which the housed sensor device is linked, possibly in a separate area or in relation to the main internet, another country. The information bounced back to the website is then relayed to the user on their hand held or similar device via the app.

From this the remote user can view the levels within the tank and alert or advise people based on site to deliver functions or carry out works, to include filling of the container, tank or vessel. Embedded technology could become apparent within this method of using Wi-Fi modules, these have become available to incorporate a real-time operating system and provide a simple means of wirelessly enabling any device which has and communicates via a serial port or variant method. This allows the design of simple monitoring devices that work remotely. Except for the smallest implementations (such as home or small office networks), Wi-Fi implementations have moved toward "thin" access points, with more of the network intelligence housed in a centralized network appliance, relegating individual access points to the role of "dumb" transceivers. Outdoor applications may use mesh topologies.

B

An example is herein disclosed that enables a user to remotely monitor and possibly interact with a static hardware device via a smart phone or related method. This Wi-Fi-enabled device can communicate via the Internet as described. The use of these sensors may not be restricted to none flammable flowing materials or liquids but it is important to state here that if senders for sensors are used within these more volatile environs, then the units that enclose the sensor devices must be of a non-flammable nature and the prevention of sparking or practical ignition would be mandatory. The apparatus includes a sensor/transmitter adapted to be manufactured as a new unit or adapted to be applied to existing sensors housed in the container, sensor/transmitter including a liquid or material quantity sensor configured and adapted to detect the amount of liquid or material within the container, a receiver that receives information related to the liquid or material in the container from a wireless electronic communication device, and a transmitter that receives information from the receiver and from the liquid and material quantity sensor, wherein the transmitter transmits information received from the transmitter and the liquid or material quantity sensor to a wireless network or Internet data receiver.

In accordance with still another aspect of embodiments of the present disclosure, a system is disclosed, the system including a single or plurality of wireless electronic communication devices, which transmit data to various hardware monitors, including smartphones, pc tablets or other, each encodable with information identifying a characteristic of liquid or material within a container.

This summary is provided to introduce a selection of the concepts that are described in further detail in the detailed description contained herein.

This summary is not intended to identify any primary or essential features of the claimed subject matter. Some or all of the described features may be present in the corresponding independent or dependent claims, but should not be construed to be a limitation unless expressly recited in a particular claim. Each embodiment described herein is not necessarily intended to address every object described herein, and each embodiment does not necessarily include each feature described.

Other forms, embodiments, objects, advantages, benefits, features, and aspects of the present disclosure will become apparent to one of skill in the art from the detailed

description and drawings contained herein.

Moreover, the various apparatuses and methods described in this summary section, as well as elsewhere in this application, can be expressed as a large number of different combinations and sub combinations. All such useful, novel, and inventive combinations and sub combinations are contemplated herein, it being recognized that the explicit expression of each of these combinations is unnecessary.

There are many ways in which the data and information can be used once it has been delivered to the smartphone or device. It may be stored on the device and sent to other group' users immediately and as a live share' and stored.

This can include instructions to them to leSsen the speed or predicted filling levels or release some material or liquid from over filled containers or vessels therein. The levels of use of this gathered data are unlimited and would relate in actions throughout known and emerging manufacturing or process techniques to improve their outcome and efficiency.

Brief description of figures

Figures 1 show an example of the sensor transmitting and internet system in use with smartphones and other viewing devices.

Figures 2 show an example of the sensor transmitting and Internet system in use with smartphones and other viewin9 devices, showing the devices returning data to the server or sensor.

Figures 3 show an example of the sensor transmifting and internet system in use with smartphones and other viewing devices, showing the devices sending instructions to other user's smartphones and devices reacting on information received from the sensors.

Detailed descriDtion of figures A typical embodiment of the invention is illustrated in Figure 1. This shows the level sensor with sender, which is housed inside a container, of fluids or flowing material. This transmits a report of the liquid or material level via the transmitting signal or internet link, as shown.

This information or data is received by a data receiver or server which processes the information, this information is then forwarded by linked or wireless local passage to the internet or a more localised Wi-Fi system which forwards the information to smartphones and Other suitable devices, as shown in Figure 1.

The receiving devices may return data or instructions as shown in Figure 2, wherein devices reply back to the internet or Wi-Fi system which is in turn able to pass this back to the data receiver and to the sender and sensor via the transmitting signal or internet link. This would enable the user to instruct decodable actions to the sending unit housed within the container. This may also be used to remotely instruct an action to the container, such as to open a valve to release or add some material or fluid to the container, without the aid of a third party.

This action of retuning information is expanded upon in Figure 3, wherein arrows show the directional flow of data to and from smartphone and other devices through the internet or Wi-Fi system, enabling instructions for work actions or other data copies of the sensors report to other device holders or users, such as staff members 1 and 2 who also work on the site, or remotely in connection with container support and maintenance.

This information is then fed back or returned to the data receiver and server to be stored, logged or interrogated by the hierarchy of the company or governing, The ability to send and receive or share information that is sent from the sensor and sender I receiver housed within the container is shown here and clearly allows this information to be used to instruct other workers from very remote locations using the internet as a vehicle to provide a universal methodology to achieve this.

The manager or main higher user can receive an actual pre-ordained screen shot from the main server of the report or status formally.

This screen shot that is captured may then be passed onto other smartphone of other device holders who are subscribed to the network and they can also go on to share this information with other or act upon it.

The ability to also use the dedicated connection from the users or user through the internet to the sensor and senderlreceiver inside the tank or container also would enable the device holder to use an app to send an automated instruction to the sender which in turn could instruct automated actions to areas within or around the container or vessel.

These may include possible instruction to add, remove, heat, chill, turn or stir the contents, with limitless options being possible providing they are within known or emerging safety guidelines.