Apparatus for determining and/or monitoring the level of a medium

An apparatus for ascertaining and/or monitoring fill level of a medium in a container. The apparatus includes an antenna, which transmits and receives high frequency signals in a predetermined oscillatory mode in a bounded space in a predetermined radiation direction, wherein, in front of the antenna in the radiation direction, an antenna protection element of a material transmissive for the high frequency signals is provided, and wherein a control/evaluation unit is provided, which evaluates the received high frequency signals and ascertains the fill level.

TECHNICAL FIELD

The present invention relates to an apparatus for ascertaining and/or monitoring fill level of a medium in a container. The apparatus includes an antenna, which transmits and receives high frequency signals in a predetermined oscillatory mode in a bounded space in a predetermined radiation direction, wherein, in front of the antenna in the radiation direction, an antenna protection element of a material transmissive for the high frequency signals is provided, from a surface of which occurring condensate of the medium runs, and/or drops, off, and wherein a control/evaluation unit is provided, which evaluates the received high frequency signals and ascertains fill level.

BACKGROUND DISCUSSION

One of a number of measuring methods for ascertaining fill level in a container is the travel time, measuring method. In the travel time, measuring method, for example, microwaves, or radar waves, are transmitted via an antenna apparatus, and echo waves reflected on the surface of the medium are received back after the distance dependent, travel time of the measuring signal. From half the travel time, the fill level of the medium in a container can be calculated. The echo curve represents, in such case, the received signal amplitude as a function of time, wherein each measured value of the echo curve corresponds to the amplitude of an echo signal reflected on a surface at a certain distance. The travel time, measuring method is essentially divided into two methods of ascertainment. Time difference measurement is a first method of ascertainment, in which the time required for a broadband, wave, signal pulse to move over a traveled path is ascertained. A further, widely employed method of ascertainment is that wherein the sweep frequency difference between a transmitted, frequency modulated, high frequency signal and the reflected, received, frequency modulated, high frequency signal is ascertained (FMCW—Frequency Modulated Continuous Wave). In the following, there is no limitation to a particular method of ascertainment.

Long used in process measurements technology are group radiator antennas, such as planar antennas or antenna arrays, horn antennas and parabolic antennas. Planar antennas are characterized by compact construction and cost effective manufacture, as compared with other antennas. Conventionally, planar antennas are designed as free field antennas, which usually radiate and receive linearly, or also circularly, polarized waves. Some embodiments of such planar antennas are described, for example, in DE 101 18 009 A1. As printed antenna structures, they differ, in turn, on the basis of their primary HF radiating element in terms of resonant structures, such as e.g. patch, slit, monopole and dipole antennas, and non resonant slit antennas, such as e.g. tapered slit antennas and Vivaldi antennas, as well as combinations of these resonant and non resonant structures. The feeding, or exciting, of the radiating elements occurs, normally, via strip lines (microstrip lines). Other line structures for the feeding of the elements, such as coplanar, and slit, lines, are likewise possible. Through simple photolithographic manufacture as printed circuits, such planar antennas are very suitable for mass production.

Another group of printed antennas, or exciting structures, are those, which produce a certain EM field distribution. As known from EP 1083413 B1, TE01 mode is produced with planar, slit radiators. This mode has for fill level measurements in bypasses and sounding tubes, as hollow conductors, the advantage, that the TE01 mode of the high frequency, measuring signal has, on the basis of its field distribution, very low attenuation and propagates almost uninfluenced by container wall disturbances, such as welded seams and holes. An option is also to work with the fundamental mode TE11 in a round, hollow conductor. A special property of the TE11 mode is that its travel velocity propagates best in the hollow conductor, in comparison with the other, higher modes.

Especially presenting problems in process measurements technology is condensation and accretion of process media on the antenna, as a result of the temperature gradient in the process tank. Thus, condensate causes major attenuation of the high frequency, measuring signal, and, moreover, the radiation characteristic, or measuring properties, of the antenna is/are altered. In the case of fill level measurements in the sounding tube, or hollow conductor, higher modes of the high frequency, measuring signal are excited, which propagate with different group travel velocities in the hollow conductor. Due to the interference of the higher modes of the high frequency, measuring signal with the wanted signal, accuracy of measurement of the system is degraded.

Fundamentally, planar antennas are disadvantaged by the disturbance sensitivity of the measuring on the basis of condensate, in comparison to horn, and parabolic, antennas, since the radiation direction of the wave is usually perpendicular to the plane, in which the antenna is oriented. For this reason, the surface of the planar antenna is orthogonal to the gravitational field of the earth, or parallel to the surface of the fill substance of the medium. The volatile components of the fill substance to be measured condense on the cold surface of the planar antenna, whereby drops form, which then only drop off after reaching a certain size, when the surface tension is no longer sufficient to hold the drops. Since the condensation of the evaporating fill substance, or medium, on the planar radiating surface of the planar antenna cannot be prevented, it is attempted to improve, via a structural measure, the dropping off, and shedding, behavior of the condensate on the planar antenna. Such an embodiment of an adapted planar antenna is described in U.S. Pat. No. 6,684,697 B1, wherein the planar antenna is inclined at an angle to horizontal H. Through the inclined position, the force of gravity has also a force component parallel to the surface of the planar antenna, whereby the condensate, driven by this additional force component (normal force), runs together to form larger drops and, at a given position, drops off. The changing of the wavefront, or the radiation direction of the radiation lobe, by the inclined orientation of the planar antenna, is compensated by a different phase control of the rows of the antenna element. Furthermore, in U.S. Pat. No. 6,629,458 B1, an embodiment of a planar antenna is disclosed, in which a filled, hollow cone is placed in front of the planar antenna as antenna protection element, or a radome with a fill material of a dielectric, thermally insulating material is emplaced, which has the same effect, such as earlier described, that the condensate can drop off of the surface of the antenna. Such antenna protection elements in the form of membranes, lenses or cones, are also applied in the case of horn antennas and parabolic antennas for protecting the reflection surfaces of the antennas from condensate formation or deposits of medium.

Disadvantageous in the case of such antenna protection elements of the state of the art is that the antenna protection element, for preventing attenuation of the high frequency, measuring signal, can only be embodied with smallest height and slope possible. Due to the small slopes of the structures, the antenna protection element sheds the condensate only poorly. Furthermore, the antenna protection elements of the state of the art excite higher disturbance modes, whereby the measuring performance of the measuring device is lessened.

SUMMARY OF THE INVENTION

An object of the invention, therefore, is to provide an antenna protection element, which has minimal attenuation losses of the high frequency, measuring signals combined with a high disturbance mode suppression, while being simple and cost effective to manufacture.

This object is achieved according to the invention by forming the surface of the antenna protection element in the radiation direction according to at least one periodic, symmetric function, which is matched to the symmetry properties of the predetermined oscillatory mode of the high frequency signals. Through the matching of the periodic function of the surface structure of the antenna protection element to the symmetry characteristics of the desired mode of the high frequency, measuring signal, it is achieved, that disturbance modes are suppressed and, simultaneously, the shedding behavior of condensate from the surface of the antenna protection element is improved.

In an especially preferred form of embodiment of the invention, it is provided, that the antenna is embodied as a planar antenna, such as, for example, a printed, patch, and/or slit, antenna.

In an advantageous form of embodiment of the solution of the invention, it is proposed, that the bounded space is embodied as a waveguide, in which the antenna transmits and receives the high frequency signals.

A purpose supporting embodiment of the apparatus of the invention is that wherein a rotationally symmetric, periodic function is provided for the surface of the antenna protection element, when the transmitting and receiving of the high frequency signals to and from the antenna occurs in a round, hollow conductor as waveguide.

In an embodiment of the apparatus of the invention, it is provided, that a translationally symmetric, periodic function is provided for the surface of the antenna protection element, when the transmitting and receiving of the high frequency signals from and to the antenna occurs in a rectangular, hollow conductor as waveguide, or directly in free field.

In an especially preferred form of embodiment of the invention, it is provided, that the periodic, symmetric function surface of the antenna protection element has maxima and/or minima, which lie in a maximum plane directed orthogonally to the radiation direction and/or which lie in a minimum plane directed orthogonally to the radiation direction.

An advantageous embodiment of the solution of the invention provides, that the periodic, symmetric function for the surface of the antenna protection element has maxima and/or minima, which lie in a maximum plane rising or falling to at least one point of symmetry and/or which lie in a minimum plane rising or falling to at least one point of symmetry.

A preferred variant of the solution of the invention is that in which at least one triangle function, at least one sawtooth function and/or at least one rectangle function is provided as symmetric, periodic function for the surface of the antenna protection element.

An especially advantageous further development of the solution of the invention provides that at least one trigonometric, at least one parabolic and/or at least one hyperbolic function is provided as symmetric, periodic function for the surface of the antenna protection element.

In a useful embodiment of the apparatus of the invention, it is provided, that the antenna protection element is embodied as a single piece of dielectric material, especially polytetrafluoroethylene (PTFE).

A suitable embodiment of the apparatus of the invention is one in which the antenna protection element is embodied in the form of a plurality of parts of dielectric materials, such as e.g. a foundational body having a chemically resistant and/or antistatic coating of a material different from that of the foundational body. A layered construction of the antenna protection element in the form of a plurality of parts simplifies, for example, the manufacture of the surface structure of the antenna protection element according to more complex, periodically symmetric functions. Moreover, additional layers can be applied on the antenna protection element for reducing adhesive forces or for improving chemical resistance.

In an advantageous form of embodiment of the invention, it is provided, that the antenna protection element is embodied of a pressure resistant, thermally insulating material. Due to the thermally insulating action of the antenna protection element, it is prevented, that condensate can form on the surface, since, in this case, the process temperature and the surface temperature are equal. Through the stability under pressure of the dielectric material of the antenna protection element, it is assured, that, in the case of high pressure of some ten to hundred bar, the antenna protection element is not pressed in and/or deformed. This is especially to be heeded, when the antenna protection element does not lie planarly against the antenna structure, but, instead, closes it, such as, for example, in the case of a horn antenna or parabolic antenna, in the manner of a lid, and, thus, forms a hermetically closed, hollow space between the antenna structure and the antenna protection element.

In view of the earlier set forth features, the invention provides the following advantages and properties: Through this construction of the antenna structure, the arising, higher disturbance modes are suppressed; the wave resistance transition from the antenna to the antenna protection element and, from there, into the process space, is matched; and the antenna exhibits good shedding of condensate, whereby only low signal attenuation is detectable.

DETAILED DISCUSSION IN CONJUNCTION WITH THE DRAWINGS

FIG. 1shows two apparatuses1of the invention for ascertaining the fill level4of a medium2in a container5. The form of embodiment of the apparatus1on the right is placed directly on the container5via a nozzle, or hatch, such that its antenna10freely radiates the high frequency signals6in the form of a linearly polarized wave with a lobe shaped radiation characteristic in the orthogonal radiation direction26toward the upper surface of the medium in the process space36. In contrast, the form of embodiment of the apparatus1on the left is placed on the container5via a nozzle, or hatch, such that its antenna10, or the exciting structure with the waveguide20secured thereto, excites the high frequency signals6in a waveguide mode, e.g. in the form of rotationally symmetric mode TE01, in a round, hollow conductor21, into the bounded space19.

The high frequency signals6are produced in the transmitting/receiving unit33of the measurement transmitter and forwarded, via the coaxial line23, or via a hollow conductor22for the signal, by means of the supply network25, to the emitting, antenna elements of the planar antenna10,11. The high frequency signals6are transmitted from the planar antenna10,11as transmission signal27into the process space36or into a bounded space19, which, for example, is embodied as waveguide20. A form of embodiment of a waveguide20is, for example, an unfilled, round, hollow conductor21, or a round, hollow conductor21filled, at least partially, with a dielectric material transmissive for microwaves. The planar antenna11and the antenna protection element14, or the radome, are, according to the invention, so matched to one another, that, during the transition of the high frequency signal6from the planar antenna11into the round, hollow conductor21, only the therein desired mode, e.g. TE01, of the high frequency, measuring signal6is produced. The exciting of higher disturbance modes8, which are also capable of propagation in the round, hollow conductor21, is prevented, or suppressed, by this type of embodiment of the antenna protection element14.

For the case of free radiating of the high frequency signals6into the process space36, the planar antenna11and the antenna protection element14are, according to the invention, so matched to one another, that the radiation characteristic of the antenna is essentially not influenced thereby. The transmitted high frequency signal27is reflected from the bounding surface of the medium2, received back by the planar antenna11and conducted back to the transmitting/receiving unit33, in which the received high frequency signals6are electronically preprocessed. The received high frequency signals6are, for example, converted in the transmitting/receiving unit33, via sequential sampling with two slightly phase shifted, high frequency, pulse sequences, into a time expanded, lower frequency, intermediate frequency signal. The reflection signal28, mixed down in this way, can then be evaluated in the low frequency portion of the control/evaluation unit34and the travel time, or traveled distance, of the transmitted high frequency signal6ascertained. Furthermore, the control/evaluation unit34performs communication tasks via a fieldbus or a two wire line24with a, for example, remote, control station or other field device. The data transmission, or communication, via the fieldbus24occurs, for example, according to the CAN, HART, PROFIBUS DP, PROFIBUS FMS, PROFIBUS PA, or FOUNDATION FIELDBUS standard. Furthermore, it is possible, such as shown in the example of an embodiment of the apparatus1on the left inFIG. 1, to perform the communication via a wireless interface35according to one of the known communication standards, such as e.g. ZigBee, Bluetooth, WLAN.

Through the particular forming of the antenna protection element14of the planar antenna11, minima18and/or maxima are provided on the surface15according to the periodically symmetric function16. By the force of gravity29counteracting the adhesive force; the condensate3forming as drops runs together and drops (at a shedding edge or a shedding point, such as, for example, a maxima17of the periodic function16of the surface15) off of the surface15of the antenna protection element14.

FIG. 2shows a plan view andFIG. 3a perspective view of a rotationally symmetric, antenna protection element14according to a first example of an embodiment. The surface15of the antenna protection element14is formed according to a periodic function16, wherein maxima17and minima18are arranged on concentric circles about a point of symmetry, or a symmetry axis,32.

Cross sections according to the theme of the first example of an embodiment are shown inFIGS. 5 and 6. Measured on the abscissa axis of the supplied coordinate system from the symmetry axis32is the radius R and on the ordinate axis the height h of the antenna protection element14. InFIG. 5, the surface15of the antenna protection element14is formed according to a periodic, triangle function16of periods N=3. InFIG. 6, the surface15of the antenna protection element14is formed according to a periodic, sine function16of periods N=3. Other functions for the structure of the surface15of the antenna protection element14with periods N=1 are indicated as dashed lines inFIGS. 5 and 6. However, also all other trigonometric and hyperbolic functions16are options for the structure of the surface15. The maxima17of the periodic function16lie all on a maximum plane30and the minima18lie all on a minimum plane31. These planes30,31are parallel to one another inFIGS. 5,6and8; however, it is also possible, that the maximum plane30and/or minimum plane31rises or falls in the direction of the symmetry axis32, so that the maxima17and minima18of the periodic function16can also lie at different heights h. It is not explicitly shown in the figures, that the maxima17of the periodic function16can lie at different heights h and, thus, that the function16can have different amplitude heights.

The antenna protection element14of the invention, with the surface15formed according to the periodic, symmetric function16, rests on the idea, that condensate3can drop by means of gravitation29off of a surface15subdivided into a number of smaller units having greater angles of inclination better than from one, all-encompassing, conical surface, and, therewith, the antenna10becomes more insensitive to the forming of condensate3. A limiting condition to the execution of this idea is, naturally, that the HF behavior of the antenna10, such as e.g. the radiation characteristic, echo losses and attenuation characteristics, must not degrade, but, instead, when possible, should even improve.

If one proceeds on the assumption, that the planar antenna11, in the ideal case, excites the desired mode7, the TE01 mode of the high frequency signal6, then a transition from the antenna protection element14to the round, hollow conductor21is to be designed, which is suited both for the matching, as well as also for the suppressing of disturbance modes8. A rotationally symmetric function16for the surface15of the antenna protection element14, on the basis of the rotationally symmetric properties of the TE01 mode of the high frequency signal6in a round, hollow conductor21, delivers very good results. Minimizing of reflection, suppressing of disturbance modes8, and the desired shedding behavior of the condensate3are all achieved by the rotationally symmetric, periodic function16for the surface15of the antenna protection element14. In order not mentionably to excite the reflected and transmitted disturbance modes8(TEOn for n>1) in a multimode, round, hollow conductor21, the number of periods N out to the hollow conductor radius R must be so selected that
2N−1>n(Eq. 1)

Here, n is the index of the highest TE0n mode, which, in this case, is still capable of propagation in the round, hollow conductor21. After the number of periods is selected for the protective element, then any periodic function16can be applied. However, the triangle function16for the surface15of the antenna protection element14is simplest to implement from a manufacturing point of view and, moreover, the additional requirements, such as the minimizing of the reflection of the mode at the dielectric transition and the optimizing of the shedding behavior of condensate3, are achievable by varying the height h of the periodic function16.

FIG. 4shows a perspective view of a second example of an embodiment of an antenna protection element14having a translationally symmetric function16for the surface15. This type of translationally symmetric, antenna protection element14is matched to the linearly polarized wave of the free field antenna and also to antennas10or exciting structures, which work with linearly, or quasi linearly, polarized mode in a waveguide20, e.g. TE10 mode in a rectangular, hollow conductor. The cross section of the translationally symmetric, antenna protection elements14can also look, for example, like the cross sections for the examples inFIGS. 5 and 6, as extended linearly in the third dimension.

Since the antenna protection elements14of the invention scarcely influence the radiative characteristics of the planar antenna11, they can also be adaptable directly on present planar antennas11.

Through the application of a chemically resistant fluoroplastic, such as e.g. perfluoroalkoxy copolymer (PFA), polytetrafluoroethylene (PTFE) and polyvinylidene fluoride (PVDF), it is possible to use the planar antenna11with the antenna protection element14in processes with aggressive media2at moderately high temperatures. Through a plasma surface treatment of the surface15of the antenna protection element14of a chemically resistant fluoroplastic, the shedding behavior of the condensate3of the surface15can be given an extra improvement, since the adhesive forces are lessened on the basis of the surface structure changed in the micrometer range by the plasma. Moreover, coatings of material transmissive for the high frequency measurement signal6are provided for improving antistatic properties, improving chemical and/or mechanical resistance and reducing the adhesive, or capillary, forces of the surface15of the antenna protection element14. Furthermore, it is possible through a, for example, multilayer coating, or a multilayered construction, of the antenna protection element14further to optimize the reflection of the signal at the transition.

FIGS. 7 and 8present diagrams of the relevant S-parameters in different modes of the high frequency, measuring signal6at the transition from the antenna protection element14to a round, hollow conductor21.

On the abscissa is measured the frequency f in 1*10^9 Hertz and on the ordinate the S-parameter as attenuation in decibel.

In the high frequency range, it is no longer possible to ascertain impedances through simple voltage and electrical current measurements. For this reason, one ascertains at predetermined locations of the impedance the reflection, transmission and absorption of the high frequency, measuring signal6in amplitude and phase. For this, the S-parameters, or scattering parameters, of the transmission path are ascertained. The input reflection coefficient S11, as reflecting part of the high frequency, measuring signal6and the forwards transmission factor S21, as transmitting part of the high frequency, measuring signal6deliver, in such case, informative values concerning the transition of the high frequency signals6from the planar antenna11with the antenna protection element14to the waveguide20.

FIG. 7presents the S-parameters of the transition from a cone shaped, antenna protection element14having a triangle function16for the surface15, which does not fulfill the condition (Eq. 1), a height h of 24 millimeter and a radius R of 66 millimeter, to a round, hollow conductor21. Here, it is easy to see, that the disturbance modes8in this form of embodiment of the cone shaped, antenna protection element14, such as, for example, the TE02 and TE03 modes, are only insignificantly suppressed in the transmitting and reflecting part of the high frequency, measuring signal6. Above a limit frequency f1of 6.6*10^9 Hertz, the TE04 mode is still only slightly attenuated in the reflecting part of the high frequency, measuring signal6.

FIG. 8shows the S-parameters of the transition from the antenna protection element14of the invention with periods N=3 of the triangle function16for the surface15, which fulfills the condition (Eq. 1), with a height h of 18 millimeter and with a radius R of 66 millimeter, to a round, hollow conductor21. From this diagram, it is evident, that the transmission characteristics at the transition of the high frequency, measuring signals6from the planar antenna11to the round, hollow conductor21are improved through the matching of the antenna protection element14by means of a periodic symmetric function16of the invention for the surface structure15. The disturbance modes8are more strongly suppressed, and, simultaneously, the part of the transmitted, desired mode7is increased—in the contrast to the results for a cone shaped, antenna protection element14illustrated inFIG. 7. Through the antenna protection element14of the invention, in the contrast to the cone shaped, antenna protection element14, thus, the dynamics of the measuring was significantly improved.

Due to the flat form of embodiment of an antenna protection element14of the invention, it is, from the point of view of construction, especially suitable for planar antennas, such as printed patch, or slit, antenna structure.

This type of embodiment of the antenna protection elements14is also adaptable for classical horn and parabolic antennas, etc., which are, however, are not explicitly displayed here. A further advantage of the antenna protection element14of the invention is its solid construction, which, in comparison to the conventional, hollow, antenna protection construction, clearly permits higher mechanical pressure loading, thus permitting exposure to higher process pressure. This is, above all, necessary for stability under pressure in the case of antennas10with antenna protection elements14with hollow spaces, such as e.g. usual in the case of horn and parabolic antennas with antenna protection elements14, in order to avoid penetration of medium2into this hollow space and/or a deformation of the antenna protection element14.