RU2799878C1 - Measuring device for process automation in industrial environment - Google Patents

Abstract

FIELD: measuring devices.

SUBSTANCE: solution is related to a measuring device for recording the physical measured parameters of the medium in a container or a tank, the use of such a device for measuring fill level, pressure, flow, as well as a method for determining the location of such a device. The measuring device (107) for recording the physical measured parameters of the medium in the tank or tank contains: the first sensor device (209) configured to register the parameter of the material in the container or a tank; a location registration device (201) configured to register the location of the measurement device; the second sensor device (208) configured to record a change in movement of the container or a tank; a control device (206) configured to analyze data about the change in the movement of the container or a tank and to determine, based on the analysis, whether or not to register the current location of the measuring device; wherein the control device is further configured to cause the location registering device (201) to register the current location of the measuring device only when analysis of the container or a tank movement change data has revealed that the measuring device has been moved and is now stopped.

EFFECT: reduction of the number of position measurements in order to reduce power consumption.

13 cl, 5 dwg

Description

The field of technology to which the invention belongs

The invention relates to process automation in an industrial environment. In particular, the invention relates to a measuring device for automating a process in an industrial environment, several applications of such a measuring device, a method for determining the location of a measuring device, a program element, and a computer-readable medium.

Prior Art

Measuring devices for process automation in an industrial environment can be used to record the physical measurable parameters of the environment in a tank or tank. Reservoirs and tanks, as a rule, have a permanently assigned location. However, there are applications where the location of the reservoir may change. An example of this is the so-called IBC containers, which are mounted on a pallet according to their purpose and are thus equipped for various uses. Thus, a plurality of such tanks can be stored at the storage site so that they can be transported to the selection (consumption) site if necessary. The tank already emptied there can be replaced with a tank from the warehouse. For the consumer who would like to be always informed about the real location and quantity of his stocks, there are tank filling level measuring devices that can transmit both the filling level and the location of individual tanks by radio to the central control room. A battery or other energy accumulator is provided to power such measuring devices.

Brief description of the essence of the invention

The object of the present invention is to provide a measurement device for process automation in an industrial environment that reliably supplies measurement data over a long period of time.

This problem is solved by the features of the independent claims. Embodiments of the invention follow from the dependent claims and the following description of the forms of execution.

The first aspect concerns a measuring device for process automation in an industrial environment. The measuring device includes a first sensor device that is configured to register a process variable, such as fill level, limit level, pressure, flow rate, topology of the surface of the feed material or the volume of the feed or bulk material.

The measurement device includes a location registration device that is configured to register the location of the measurement device. Examples of this are GPS positioning devices or those using Galileo, GLONASS, Beidou, mobile radio signals, Bluetooth, or so-called “indoor positioning”.

A second sensor device is provided that is configured to capture environmental data. Such environmental data may be, for example, acceleration data, location data (eg, mobile radio signals), compass data, and/or wake-up data (button press or finger proximity detection).

The measuring device has a control device configured to analyze the environmental data and to determine, based on this analysis, whether or not the current location of the measuring device should be recorded by the location recorder. The control device is further configured to cause the location recorder to record the current location of the measuring device if the analysis of the environmental data reveals that the current location should be recorded.

In this way, energy can be saved, since the location recorder is only used for the current location record when it is needed, for example because the position of the measuring device has changed due to a movement of the tank.

The terms "first sensor device", "second sensor device", "location recorder" and "control device" should be interpreted in a broad sense. It is important that these individual devices are configured to perform the intended activities, whether they are interconnected units or partial units located at different locations on the measuring device.

The term "process automation in an industrial environment" can be understood in relation to the branch of technology, which contains all the activities for the operation of machines and equipment without human interaction. The goal of factory automation is to automate the joint operation of individual components of manufacturing equipment in industries such as the chemical, food, pharmaceutical, oil, paper, cement, shipping or mining industries. For this, a plurality of sensors can be used, which are adapted in particular to the specific requirements of the process industry, such as, for example, mechanical stability, insensitivity to contaminants, extreme temperatures and extreme pressures. The measured values of these sensors are usually transmitted to the control room, where process parameters such as fill level, level limit, flow rate, pressure or density are monitored and settings for all production equipment can be changed manually or automatically.

The sub-field of factory automation in an industrial environment refers to logistics automation. With the help of distance and angle sensors, in the field of logistics automation, processes within a building or within individual logistics equipment are automated. Typical applications are, for example, systems for automating logistics in the field of baggage and cargo acceptance at airports, in the field of traffic control (toll road systems), in trade, parcel delivery or also in the field of building security (access control). The above examples have in common that presence recognition is required in combination with an accurate measurement of the size and position of the object from the respective application side. For this, sensors (sensors) based on optical measurement methods with a laser, LED, 2D cameras or 3D cameras can be used, which record distances according to the propagation time principle (time of flight, ToF).

Another sub-field of factory automation in an industrial environment concerns manufacturing/manufacturing automation. Applications for this can be found in various industries such as the automotive, food, pharmaceutical, or, more generally, packaging industries. The goal of factory automation is to automate the production of products by machines, production lines and/or robots, i.e. ensure the execution of processes without human intervention. The sensors used for this and the special requirements regarding the accuracy of measurements when registering the location and size of an object are comparable to those in the previous example of logistics automation.

Accordingly, an aspect of the present disclosure relates to an independent fill level measuring device for measuring the filling level in a tank, the fill level measuring device including:

a filling level measurement unit (first sensor device) configured to measure the filling level of a reservoir, tank or the like;

at least one transmit/receive unit (eg LoRaWan) configured to communicate with the data processing unit;

- a positioning module (eg GPS/Galileo/Glonass/Beidou/Beacon) (location recorder);

- a sensor for recognizing environmental data (second sensor device);

- an evaluation logic (controller) which determines, based on the environmental data, whether a position update should be triggered;

- energy storage (capacitor/battery) to power the components.

According to the embodiment, the location recorder is configured to record the current location of the measuring device only when the environmental data analysis has determined that the current location should be recorded. Otherwise, the current location of the measuring device is not registered.

According to another embodiment, the measuring device has a data memory that is configured to store the current location of the measuring device. Then, at a later point in time, the measured current location of the measuring device, optionally together with the measured data associated with the recording of the process variable, can be transmitted to an external device, usually by means of a radio transmission. The transmission can also be done by wire, for example, over a two-wire 4 to 20 mA line.

According to the embodiment, the measuring device is an independently operating measuring device with an exclusively internal energy supply in the form of a battery or one or more other energy accumulators.

According to another embodiment, the control device is configured to cause the location registering device to only register the current location of the measuring device when the analysis of environmental data has revealed that the measuring device has moved. In particular, it can be provided that the current location of the measuring device is recorded only when the analysis of the environmental data has revealed that the measuring device has moved and is now actually at rest. This can further reduce the number of location measurements.

According to another embodiment, the control device is configured to recognize the pattern (pattern, pattern, pattern) of movement of the measuring device from an analysis of environmental data. Artificial intelligence can be used for this. For example, the controller may be configured to recognize that the meter has moved with the tank and then stopped. In response, a location determination may be triggered.

According to another embodiment, the measuring device comprises an energy accumulator. It may also include a switch that is configured to close the connection between the power storage device and the location recorder powered by the energy storage device. If the switch is closed, the location is determined by the location recorder.

According to another embodiment, the second sensor device comprises an acceleration sensor, a positioning device using mobile radio signals, a compass and/or a current meter.

Another aspect concerns the use of the measuring device described above and below for measuring the filling level. Another aspect concerns the use of the pressure measuring device described above and below. Another aspect relates to the use of the above and further described measuring device for measuring flow. Another aspect relates to the use of the measuring device described above and below to measure a process parameter, such as the fill level, the topology of the surface of the feed material, or the amount of feed material in the mobile tank.

Another aspect relates to a method for determining the location of a measuring device, in which a process variable is recorded, environmental data of the measuring device is recorded, this environmental data is analyzed and it is determined, based on the analysis, whether or not the current location of the measuring device should be recorded. This analysis is followed by the recording of the current location of the measuring device, if the analysis of the environmental data has determined that the current location should be recorded. Otherwise, it should not be registered.

Another aspect relates to a software element which, when executed on the control device of the measuring device, causes the measuring device to perform the above and further described steps of the method.

Another aspect relates to a computer-readable medium on which the above-described program element is stored.

The computer program may, for example, be loaded and/or stored in the working memory of a data processing device, such as a data processor, and the data processing device may also be part of an embodiment of the present invention. The data processing device may be configured to perform the steps of the method described above. The data processing device may furthermore be configured to automatically execute a computer program or method and/or accept user inputs. The computer program may also be provided over a data network, such as the Internet, and from such a data network be downloaded to the working memory of a data processing device. The computer program may also include updating an already existing computer program, whereby the existing computer program is able, for example, to carry out the method described above.

The computer-readable storage medium may in particular, but not necessarily, be a non-volatile medium which is suitable in particular for storing and/or distributing a computer program. The computer-readable storage medium may be a CD-ROM, DVD-ROM, optical storage medium, solid state media, or the like, which is supplied with or as part of other hardware. Additionally or alternatively, the computer-readable storage medium may also be distributed or sold in another form, such as over a data network such as the Internet or other wired or wireless telecommunications systems. To this end, the computer-readable storage medium can be embodied, for example, as one or more data packets.

The embodiments of the invention are described below with reference to the drawings. The depiction in the drawings is not to scale. When the same reference numbers are used in the following description of the drawings, they denote the same or similar elements.

Brief description of the drawings

Fig. 1 shows a tank with a measuring device in it.

Fig. 2 shows the structure of the measuring device according to the embodiment.

Fig. 3 shows a flowchart according to the execution form.

Fig. 4 shows a flowchart of a method according to another embodiment.

Fig. 5 shows the structure of the measuring device according to another embodiment.

Detailed description of execution forms

Fig. 1 shows an example of a so-called IBC container 101 which is used to transport various media. This weight-, volume- and cost-optimized design is particularly attractive in the distribution and logistics industries and enables easy supply of a wide variety of media to consumers. The IBC container 101 typically consists of a tray 102, a metal frame 103, and an inner container 104, usually made of plastic, which contains the feed material 105. Through the lid 106, the medium 105 can be placed in the container 101 or, respectively, the inner container 104.

The measuring device 107 may be, for example, a fill level measuring device, which is usually attached to the upper surface of the inner container 104, and its first sensor device, for example, using electromagnetic waves, measures the distance to the surface 105 of the loaded material. The measuring device 107 may then provide the measurement result to the outside.

In addition, the measurement device 107 contains a communication module for wireless communication (eg, narrowband oT, LPWA (low power, wide coverage), Lora, Sigfox, MIOTY, LoRaWAN, Bluetooth communication). In addition, the measuring device 107 includes a positioning unit (location registration device) and an additional sensor (second sensor device) whose data is used to decide whether or not to perform positioning. Only if the evaluation logic (control device) recognizes that a location update is required, the location module is supplied with sufficient power. The purpose of this is to reduce power consumption for positioning.

One aspect is the coordinated interaction between the control device, the location module and the second sensor device to recognize if an update of the location data is required. The positioning module (GPS/Galileo/Glonass/Beidou/Handy-Netz/Bluetooth/Indoor positioning) requires a lot of power during operation and should therefore only be activated for a short time. The sensor for recognizing whether it is necessary or advisable to update the location data may be, for example, an acceleration sensor or a simple contact probe. The power consumption of this sensor is noticeably lower than the power consumption of the location module. Therefore, the invention makes it possible to reduce the overall power consumption of the measuring device.

The power supply of such measuring devices is mostly carried out wirelessly, otherwise the flexibility would be greatly reduced. Therefore, independent solutions are needed using energy storage devices that guarantee the power supply of the measuring device. Those. all components of the measuring device are supplied with energy from at least one energy accumulator. It is also possible some form of Energy-Harvesting (collection and storage of energy from the environment), in which, for example, through photovoltaics, the energy storage can be recharged. However, the requirement that each individual component of the measuring device, as far as possible, does not consume unnecessary energy, is extremely important. Therefore, it is necessary to reduce to a minimum especially energy-consuming processes, such as positioning.

From the above application case, which describes that the tank first remains at the storage location, and after a certain time is transported to the consumption location, it is easy to see that locating the measuring device is only required at exactly two locations. The first time the location data needs to be updated for the location data permanently stored in the measuring device is when the tank with the measuring device reaches its permanent storage location. Then, the location does not change for a long period of time, and the location may be deactivated to save power.

It is possible to completely cut off the power supply by means of a circuit, a switch or a transistor, or also a solution in which the location module is put into a power-saving state. The measuring device is configured in such a way that after a certain period of time it prompts the execution of a measurement value registration, for example a fill level measurement, and provides the measured value (fill level) with the last stored location data via the radio module to the user. This process can be repeated sequentially. The fill level measuring device supplies correct location data until the tank is moved again. During this period of time, the location module may remain deactivated. An update of the position data is not required since both the tank and the level gauge remain stationary. Only when the tank in the example shown reaches the point of consumption is it advisable to update the location data. The control device recognizes by means of the measured data (environment data) of the second sensor device whether updating of the position data is necessary, supplies power to the position determination module, and updates the existing position data. A new measurement can then be called and the updated location data with the fill level of the tank sent via the radio module.

Whether positioning is required during transport of the tank and whether the measuring device then updates its position data regularly when forwarded via the radio module can, under circumstances, be determined by the user himself and communicated to the measuring device via a parameterization interface or a parameter setting interface. According to another form of implementation, in addition, the transmission of location data is established during the movement of the tank. Alternatively, it can be provided that, instead of position data, a status is transmitted by means of a radio module, which signals that the measuring device and the container are moving.

For the second sensor device, which registers environmental data, which is then evaluated to decide whether to update the location data, various forms of implementation are possible, which find their practical use alone or in combination:

Contact probe (probe)/switch:

In the simplest case, the second sensor device is represented by a contact probe or a switch. The ambient data are then the pressure on the contact probe, the closing of the contact with a finger or an aid, or a change in capacitance in the case of a capacitive probe. The activation of the contact probe/switch must be done manually as soon as the tank with the measuring device reaches its destination.

Acceleration sensor:

The acceleration sensor recognizes that the tank with the measuring device is moving. The acceleration sensor has a very low power consumption. In addition, it is possible to equip the acceleration sensor with a neural network or other type of artificial intelligence in order to respond only to a certain movement pattern. Uniform movement, which entails a change in location, can thus be distinguished from non-essential vibration.

Simple forms of sensors are also possible, which detect movement, for example, in that a thin metal plate closes a contact.

The advantage is that the update of the location data is only performed when it is recognized that the tank has reached its destination. So, for example, after accelerating for some waiting time, it can be observed whether further acceleration is carried out. Only when it is guaranteed that the tank has reached a permanent location, then a location update can be performed. This is where motion pattern recognition comes in handy. In this way, it can be recognized whether the container is moved first and then removed.

Radio cell recognition:

A sensor or a communication module, which recognizes the current radio cell of the mobile radio network or the reception amplifiers of different towers and, when the reception characteristics change, concludes that the location has changed, which is then verified by the location module.

Timer:

A timer that cycles through location updates.

Compass:

A compass whose orientation is continuously recorded and updates the position data as it changes.

Current meter when collecting and accumulating energy from the environment (Energy-Harvesting):

If the measuring device has devices for collecting and storing energy from the environment, then the sensor can evaluate whether there is currently excess or at least sufficient energy to update the location data.

Fig. 2 shows the operation of the measuring device according to the embodiment. The positioning module 201 (location recorder) for receiving location data 210 via line 202 is supplied with power from an energy accumulator 204 (battery, capacitor). Line 202 includes a switching device 203 (mechanical switch, transistor, circuit) with which the positioning module 201 can be disconnected from a power source or supplied with power. The switching device 203 can be acted upon via the control line 205 by the control device 206 (microcontroller, logic circuit). The controller 206 or microcontroller 206, respectively, may additionally perform other functions. The connections to the positioning module 201, to the radio module 207 and to the sensor for registering fill levels 209 are shown in the drawing. These connections can exchange analog or digital signals/data. Connected to the control device 206 itself is an additional sensor 208 whose data can decide whether an update of the location data is required, as well as a data storage device 210 for storing the location data and measured data.

So, for example, the control device 206 may first register the fill level with the fill level sensor 209, then decide by evaluating the data from the sensor 208 whether the positioning module 201 should be powered in order to request an update of the location data from the positioning module 201. Finally, all collected information is transmitted via the radio module 207. The data transmission 211 can then be received by the user and evaluated.

Fig. 3 shows the individual steps for updating location data. At step 301, the location module is powered. At block 302, wait until the location is completed. In step 303, the location data is transmitted from the location module to the control device. At step 304, the control device stores the location data. At step 305, the power supply to the positioning module is disconnected, or the module itself is placed in a dormant state.

Fig. 4 shows the main steps in the execution of the program of the fill level measuring device. At step 401, a filling level measurement is performed. In step 402, the measured fill level value is transmitted by the radio module. In step 403, the stored location data of the last location data update is transmitted by the radio module. At 404, sensor data (environmental data) is recorded and evaluated. At step 405, it is checked if the location data needs to be updated (FIG. 3). Next, at block 406, the location data is updated.

It should be noted that the sequential execution of the program, as shown in Fig. 4 is only an example. It is also possible that the sensor 208 triggers an interrupt, which then simultaneously causes the location data to be updated. It is also possible that, under circumstances, the externally located environmental sensor has its own estimation logic (e.g., an artificial neural network), which then, via its own control line, informs the main control line assessment logic that an update of the location data is required.

Fig. 5 shows a modification of the embodiment of FIG. 2. Here, the switching device 203 and the control line 205 are missing. The drawing shows that there is also a location module that can be put into a power-saving state, or even can be switched to an internally de-energized state.

Additionally, it should be noted that the terms "including" and "comprising" do not exclude other elements or steps, and the singular form does not exclude the plural. In addition, it should be noted that features or steps that have been described with reference to the above exemplary embodiments can also be used in combination with other features or steps of other exemplary embodiments described above. Reference positions in the claims should not be considered as limitations.

Claims (29)

1. Measuring device (107) for recording the physical measured parameters of the medium in the reservoir or tank, containing: a first sensor device (209) configured to register a material parameter in the reservoir or tank; a location registration device (201) configured to register the location of the measurement device; a second sensor device (208) configured to record a change in movement of the tank or tank; a control device (206) configured to analyze data about the change in the movement of the tank or tank and to determine, based on the analysis, whether or not to register the current location of the measuring device; wherein the control device is further configured to cause the location registering device (201) to register the current location of the measuring device only when analysis of the tank or tank movement change data has revealed that the measuring device has been moved and is now stopped. 2. Measuring device (107) according to claim 1, wherein the location recorder (201) is configured to record the current location of the measuring device only when the analysis of the change in movement of the tank or tank has determined that the current location should be recorded. 3. The measuring device (107) according to any one of the preceding claims, further comprising a data memory (210) configured to store the current location of the measuring device. 4. Measuring device (107) according to any of the previous paragraphs, wherein the control device (206) is configured to cause the location registering device (201) to register the current location of the measuring device only when analysis of the change in movement of the tank or tank has revealed that the measuring device has been moved. 5. Measuring device (107) according to any of the previous paragraphs, and the control device (206) is configured to recognize the movement pattern of the measuring device from the analysis of data about the change in the movement of the tank or tank. 6. Measuring device (107) according to any one of the previous paragraphs, further comprising: energy accumulator (204), a switch (203) configured to close the connection between the energy storage device and the location registration device (201). 7. Measuring device (107) according to any of the previous paragraphs, and the second sensor device (208) contains an acceleration sensor, a device for determining the location by means of mobile radio signals, a compass and/or a current meter. 8. The use of a measuring device (107) according to any one of paragraphs. 1-7 for filling level measurement. 9. The use of a measuring device (107) according to any one of paragraphs. 1-7 for pressure measurement. 10. The use of a measuring device (107) according to any one of paragraphs. 1-7 for flow measurement. 11. The use of a measuring device (107) according to any one of paragraphs. 1-7 to measure the material parameter in the mobile tank. 12. Method for determining the location of the measuring device, comprising the steps: registering a material parameter; registration of data on changes in the movement of the tank or tank of the measuring device; analysis of data on changes in the movement of the reservoir or tank; determining, based on the analysis, whether or not to register the current location of the measuring device; registering the current location of the measuring device only when the analysis of the data on the change in the movement of the tank or tank has revealed that the measuring device has been moved and is now stopped. 13. A computer-readable medium that stores a software element that causes the measurement device of claim 1 to perform the steps of the measurement device location method of claim 12.

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