RADAR SENSOR WITH SPHERICAL SENSOR HOUSING

Abstract

Radar sensor with an at least sectionally spherical sensor housing, which is rotatably mounted in a mounting device. For example, the sensor housing is spherical.

Claims

1. Radar sensor (100) configured to measure a level or a limit level of a product (201) in a container (200), comprising: a sensor housing (101), the outer contour of which has the shape of a spherical segment at least in a first partial region (102) of the sensor housing, which is configured to rotatably support the radar sensor in a corresponding hollow spherical segment (301) of a mounting device (104); an electronics unit (105) configured to generate a measurement signal; an antenna unit (106) configured to radiate the measurement signal and to receive the measurement signal reflected from a product surface; wherein the electronic unit and the antenna unit are arranged in the housing.

2. Radar sensor (100) according to claim 1, wherein the outer contour of the sensor housing (101) is completely spherical.

3. Radar sensor (100) according to any one of the preceding claims, wherein the sensor housing (101) is completely closed.

4. Radar sensor (100) according to any one of the preceding claims, wherein the sensor housing (101) is made of plastic at least in the region of the antenna unit (106), so that the measurement signal can be radiated through the sensor housing.

5. Radar sensor (100) according to any one of the preceding claims, wherein the sensor housing (101) cannot be opened non-destructively.

6. Radar sensor (100) according to any one of the preceding claims, configured as a stand-alone radar sensor with its own power supply.

7. Radar sensor (100) according to any one of the preceding claims, further comprising: a radio interface (107) configured for wireless transmission of the radar sensor data to an external receiver.

8. Radar sensor (100) according to any one of the preceding claims, where the center of gravity of the radar sensor is located below the center point of the sphere segment, so that the radar sensor aligns itself perpendicular to the product surface by means of gravity.

9. Radar sensor (100) according to any one of the preceding claims, wherein a second portion (108) of the sensor housing (101) is made of a translucent material such that a display (109) of the radar sensor can be read through the sensor housing.

10. Radar sensor (100) according to any one of the preceding claims, configured for non-contact measurement of the filling level or limit level.

11. Mounting device (300), comprising a hollow sphere (301, 302) or at least one hollow sphere segment (301), configured for rotatably mounting a radar sensor (100) according to any of the preceding claims.

12. Mounting device (300) according to claim 11, embodied as a closed hollow sphere.

13. Mounting device (300) according to claim 11 or 12, wherein the hollow sphere segment (301) is made of opaque plastic.

14. Mounting device (300) according to any one of claims 11 to 13, wherein the hollow sphere (301, 302) is at least partially made of a translucent material such that a display (109) of the radar sensor (100) can be read through the hollow sphere (301, 302).

15. Mounting device (300) according to any one of claims 11 to 14, comprising a mounting flange for attachment to the opening of a container. cm 16. Mounting device (300) according to any one of claims 11 to 15, comprising a retaining arm (310) or an internal thread for attaching a retaining arm (310).

17. Mounting device (300) according to any one of claims 11 to 16, wherein the mounting device comprises a locking element (311) configured to fix the sensor (100) in the mounting device.

18. Mounting device (300) according to any one of claims 11 to 17, wherein the mounting device comprises an alignment member (312) configured to align the sensor (100) in the mounting device.

19. Mounting device (300) according to any one of claims 11 to 18, comprising a sensor (100) disposed therein.

20. Mounting device (300) according to claim 19, wherein the sensor (100) is a level meter, a point level sensor, a pressure sensor, or a flow sensor.

21. Use of a mounting device (300) according to any one of claims 11 to 20 for mounting a sensor (100) selectively on a side wall of a container (200) or the ceiling of the container.

22. Container (200) having a mounting device (300) attached thereto according to any one of claims 11 to 20.

23. Method of mounting a sensor (100) to a container (200), comprising the steps of: Placing the sensor in a fully enclosed mounting device (300); Attaching the mounting device to the container; Aligning of the sensor.

24. Method according to claim 23, wherein aligning of the sensor (100) is performed by gravity.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0040] FIG. 1 shows a measurement setup according to a first embodiment.

[0041] FIG. 2 shows a measurement setup according to a further embodiment.

[0042] FIG. 3 shows a flow diagram of a process according to an embodiment.

[0043] FIG. 4 shows a section of a radar sensor with mounting device in the area of the sensor bearing.

DETAILED DESCRIPTION OF EMBODIMENTS

[0044] FIG. 1 shows a measurement setup according to an embodiment. The measurement setup has a radar sensor 100 that is mounted in a mounting device 300 in such a way that it can rotate in all spatial directions. The mounting device 300 is attached to the opening of the container 200, for example by means of a flange mounting 313, but other mounting may also be provided and the invention is not limited to a flange mounting.

[0045] Importantly, the radar sensor 100 is rotatably mounted in the housing of the mounting device 300.

[0046] The radar sensor, which is configured to measure the level or limit level of the product 201, comprises a sensor housing 101, an electronics unit 105 and an antenna unit 106. The sensor housing 101 may be spherical in shape or, alternatively, may have a portion that is shaped like a spherical segment. In the embodiment shown in FIG. 1, the sensor housing is a solid sphere made of plastic and contains the electronics unit 105, the antenna unit 106, the energy storage 110, and a wireless communication module 107.

[0047] The wireless communication module 107 may also be referred to as a radio interface. Also, a display 109 may be provided which is located, for example, near the top of the housing so that it can be read through the wall of the housing. For this purpose, the upper, second partial area 108 of the housing is made of translucent material, for example a transparent plastic. Since the spherical electronics unit 100 is completely contained within the outer sphere 300, the sub-region 108 can be saved and the electronics can be placed openly, without an additional housing, within the outer sphere 300.

[0048] The lower portion of the housing, further referred to above as the “first sub-region” 102, may also be made of plastic. However, this sub-region need not be translucent; it is sufficient for radar beams emitted from the antenna unit 106 towards the medium to be filled to be translucent. Again, the antenna would not need to be within a housing. It would already be protected by the outer sphere and could be exposed so that it would only be necessary to measure through the outer sphere. In other words, the inner sphere may be reduced to a spherical segment disposed within the socket of the mounting device 300.

[0049] The radar sensor 100 is located entirely within the mounting device 300, so the unit may have two parts, a mounting device 300 and a separate radar sensor 100. In another embodiment, the mounting device 300 represents the housing of the radar sensor 100, so the unit 100 could also be referred to as a spherical or spherical segment electronic unit without its own housing.

[0050] The mounting device 300 may be a hollow sphere or a hollow sphere segment. Similar to the radar sensor, the housing of the mounting device 300 can also consist of two different materials: First, a hemisphere or hollow sphere segment 301 in the lower region that is transparent to radar beams and an upper hollow sphere segment 302 in the upper region that are detachably or non-detachably connected to each other. The upper hollow sphere segment 302 may be made of the same material as the lower hollow sphere segment, or it may be made of a different material, such as a translucent material, such as a transparent plastic.

[0051] A locking element 311 may be provided, for example in the form of a set screw threaded into a continuous internal thread through the wall of the mounting device 300 to clamp the sensor 100 in place.

[0052] Also, an alignment element 312 may be provided by means of which the orientation of the sensor 100 can be manually adjusted, for example magnetically through the plastic wall.

[0053] It may be provided that the center of gravity of the sensor is located in the area of the antenna unit 106, in any case well below the center of the spherical radar sensor 100, so that the mounted “sensor sphere” automatically adjusts itself by means of gravity so that the antenna measures in the desired direction (usually vertically; however, horizontal measurement or measurement in another direction may also be provided).

[0054] Also, the radar sensor can have a tilt sensor that detects the current orientation of the sensor. This data can help to detect or calculate the level more accurately.

[0055] An attachment of the radar sensor 100 to the container 200 is thus provided, which allows the antenna unit 106 to be rotated and pivoted in all directions. The device can be manufactured inexpensively in this case.

[0056] For example, the mounting device 300 is designed as a two-piece hollow sphere. The radar sensor 100 is spherical in shape and can thus be accommodated in the hollow sphere housing and thus rotated and pivoted in all directions.

[0057] The spherical radar sensor 100 can be fixed, for example, by the upper half shell of the hollow sphere. The radar antenna, which is part of the electronics, can thus be pivoted and fixed in all possible positions. Here, measurements are taken through the outer housing sphere 301, 302, which is made of plastic.

[0058] The mounting device can be placed in any round hole of the container that is smaller in diameter than the diameter of the sphere and can be glued in place using a silicone bead, for example. Alternatively, the mounting device 300 can be attached to the container by means of a rod 310 (cf. FIG. 2) or a clamping device so that the spherical mounting device is located outside the container.

[0059] If the upper hemisphere 302 is made of transparent plastic, a display or light indicator located inside can be read through the housing wall. Alternatively, it may be provided that the radar sensor 100 is merely inserted into the hemisphere-like housing portion 301 so that it can be easily replaced.

[0060] Thus, a spherical device housing is provided that includes a spherical electronics cup with antenna so that the antenna can be vertically oriented in the spherical housing.

[0061] If the radar sensor 100 is placed on the container opening with its hollow sphere-like mounting device 300, as shown in FIG. 1, the lower part of the hollow sphere protrudes into the container. This hollow sphere houses the electronics with antenna, which is also in the form of a sphere. The upper part of the sphere housing can be made with transparent plastic so that any display inside remains visible.

[0062] A radio interface (wireless module) 107, which uses Bluetooth for example, is provided for communication with an external unit and in particular for measured value transmission or parameterization. To enable completely autonomous operation of the radar sensor, an energy storage device 110, for example a rechargeable battery, can be used.

[0063] If no opening in the container is desired, the attachment device 300 can also be mounted to the container, for example, by means of a rod 310, so that it “floats” above the container (see FIG. 2).

[0064] FIG. 3 shows a flow diagram of a method according to an embodiment. In step 1, the sensor 100 is arranged in a fully or partially enclosed mounting device 300. In step 2, the mounting device is attached to a container, and in step 3, the sensor is aligned so that it emits the measurement signal perpendicular to the product surface. The alignment can be done automatically by gravity. In step 4, the sensor is locked in place, whereupon the level measurement takes place.

[0065] FIG. 4 shows a section of a radar sensor with mounting device in the area of the sensor mounting. This is the embodiment already described above, in which the mounting device represents the “sensor housing” and the electronics of the sensor are movably mounted in the joint socket of the mounting device.

[0066] Supplementally, it should be noted that “comprising” and “having” do not exclude other elements or steps, and the indefinite articles “a” or “an” do not exclude a plurality. It should further be noted that features or steps that have been described with reference to any of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be regarded as limitations.