GB2578607A

GB2578607A - Level sensing apparatus

Info

Publication number: GB2578607A
Application number: GB1817818.6A
Authority: GB
Inventors: Franks James
Original assignee: HWM Water Ltd
Current assignee: HWM Water Ltd
Priority date: 2018-10-31
Filing date: 2018-10-31
Publication date: 2020-05-20
Also published as: GB201817818D0

Abstract

A level sensing apparatus is provided for mitigating against the effects of sensor misalignment during use, the level sensing apparatus comprising a distance sensor 20 arranged to detect a level 22 in a container. The level sensing apparatus comprises an alignment detecting member 23, the alignment detecting member detects an alignment of the distance sensor. The level sensing apparatus comprises one or more output nodes arranged to output the level and/or the alignment to one or more output members. The level sensor may comprise an ultrasonic transducer, optical distance sensor, infra-red, laser, radar. The alignment detecting member may comprise an accelerometer, gyro sensor, compass, magnetometer, MEMS, NEMS, laser, hall effect sensor, motion sensor, proximity sensor. The location of the level sensor may also be detected. Change in location due to the level sensing apparatus being dislodged may be detected and alerted. The level sensing apparatus aims to inform a user of a misalignment of the level sensing apparatus during use, and thereby overcome issues with diminishing accuracy of such sensors over time.

Description

Level Sensing Apparatus

Field of the Invention

The present invention relates to level sensing apparatuses, and in particular level sensing apparatuses for use in detecting the level of a content in a container.

Background to the Invention

Level sensing apparatuses are used within a number of industries to determine content level and/or depth. An example of such an apparatus can be found in, for example, WO 2008/132470. One example of such an industry is the waste water industry, in which distance sensors are used to determine brown water depth.

Such level sensing apparatuses are invariably installed within a content container or above an open channel and facilitate the detection of the level of said content. During installation, a sensing apparatus is acutely positioned such that a distance sensor on the apparatus is aligned with the surface of said content.

Post installation it is possible for one or more of a number of events to reposition, move, dislodge or realign the apparatus such that the sensor is no longer accurately aligned with the surface of said content. Such events might include debris, flood events, ragging or human intervention such as during inspection, jetting, maintenance or repair of the content container or apparatus. It may be the case that after such an event, the depth or level of said content that is reported or displayed by said level sensing apparatus is no longer accurate.

Technological advancements have driven an increase in remote monitoring, particularly in pipeline and utilities monitoring industries. Remote content level monitoring often causes level sensing apparatuses to be positioned in hard-to-reach locations requiring specialist skill and equipment, along with extensive man hours, to reach.

In instances where such remote apparatuses are located in difficult-to-reach areas, the cost of inspection, maintenance or repair of said remote apparatuses is compounded by the skill and effort required to reach the location, and the resultant need for additional labour time, equipment and skilled manpower.

In many cases where a level sensing apparatus has been moved, through one of any number of possible scenarios discussed above, information provided by the apparatus relating to the depth or level of a content is often plausible, but inherently incorrect. The plausibility of such data poses further disadvantages and is a major concern for utilities management providers, since misinterpreted readings and false negatives can result in undue load on a system, accelerating degeneration of such a system and therefore reducing its lifetime and increasing the cost of management, maintenance, repair and replacement. False positives can be a key cause for unnecessary labour in locating and inspecting an apparatus, particularly if positioned in a hard-to-reach area, resulting in a waste of skilled man hours.

One example of a solution provided to address these problems is to increase the density of level sensing apparatuses per unit area, or increasing the number of distance sensors, such as in WO 2008/132470. In-built redundancy often aims to identify unreliable results and potentially faulty apparatuses, potentially by taking into accounts the level measurements performed by a plurality of apparatuses or sensors. An increased number of apparatuses, and necessary installations, and/or sensors-per-apparatus requires a greater level of financial commitment from a utilities management company and provides the disadvantage of increased complexity in a system, increasing maintenance and repair costs along with the likelihood of errors.

As such, cost and unreliability are examples of the many limitations faced by current technology, driving an effort to deskill installation processes and reduce the incidence of false negatives and false positives by sustaining the accuracy of such technology over a more prolonged period of time.

It is therefore desirable to provide an apparatus which enables the deskilling of the installation process for level sensing apparatuses, and preferably to overcome current issues with diminishing accuracy over time.

Summary of the Invention

In accordance with a first aspect of the present invention, there is provided a level sensing apparatus comprising a distance sensor arranged to detect a level of a content in a container, wherein the level sensing apparatus further comprises an alignment detecting member, the alignment detecting member arranged to detect an alignment of the distance sensor; and one or more output nodes arranged to output the level and/or the alignment to one or more output members.

Preferably the level sensing apparatus comprises said one or more output members.

Embodiments will be appreciated wherein the apparatus is arranged to communicate with an output member. Additional embodiments will be appreciated comprising said output members.

The present invention proposes the incorporation of an alignment detecting member within a level sensing apparatus, preferably to facilitate a determination of sensor alignment/orientation during installation and/or sensor movement post-installation, and preferably facilitating the alerting of a user to said sensor alignment/orientation and/or sensor movement.

Due to the required accuracy of level sensing apparatuses of the available technology, and the need for correct alignment of the apparatus with the surface of a content, skilled manpower and surplus equipment, such as aiming kits for example, are often required for installation of level sensing apparatuses. Preferably, by providing an on-board detection and reporting of an alignment/orientation of a level sensing apparatus, a reduced level of skill and/or a reduction in auxiliary installation equipment is required to install the apparatus of the present invention.

A large number of possible events may result in the repositioning or misalignment of a level sensing apparatus, potentially resulting in the provision of plausible but fundamentally incorrect measurements. The present invention preferably enables a user to cross-reference level measurements with alignment/orientation data, preferably in order to determine the reliability of the level measurement. Such cross-referencing can also preferably act to inform a user of the requirement for maintenance and/or repair of a level sensing apparatus, and whether a realignment or repositioning of the apparatus is required. For instance, if a non-plausible level measurement is provided and the alignment appears normal, the level sensing apparatus may need repair or replacement. On the other hand, if a plausible level measurement is provided and the alignment appears atypical, a realignment of the apparatus may be required. Such decisions can preferably be made with more confidence using the present invention.

Preferably the distance sensor is an ultrasonic distance sensor. Preferably the ultrasonic distance sensor comprises an ultrasonic transducer, which may be an ultrasonic level sensing transducer.

Ultrasonic level sensing transducers are often preferably advantageous due to having no moving parts, therefore preferably reducing the likelihood of failure through repetitive motion, friction and wear and tear. Such transducers can preferably measure the level of a content without making physical contact with said content. This preferably makes ultrasonic level sensing transducers optimal for measuring content levels in containers housing hazardous contents such as sewage or waste water. Accuracy of level sensing using ultrasonic transducers is maintained during changes to the composition of a content, which can be variable in the case of sewage or waste water.

Embodiments will be appreciated wherein the distance sensor is not an ultrasonic distance sensor. In such embodiments, the distance sensor may comprise an optical distance sensor; an infra-red distance sensor; a laser; and/or a radar. Embodiments will be appreciated wherein the distance sensor comprises any suitable means for detecting a level of the content using a distance measurand.

Preferably the one or more output members comprise a display member arranged to display the level and/or the alignment to a user.

On-board reporting of level and/or alignment to a user is preferably advantageous in providing an easier installation and inspection of an apparatus according to the present invention.

Preferably the one or more output members comprise a transceiver arranged to transmit the level and/or the alignment to a receiver. Preferably the transceiver is arranged to transmit the level and/or alignment to the receiver using a communication technology selected from the group: wired communication; wireless communication; short-range wireless communication; long-range wireless communication; radio signal; mobile communication technology; optical fibre communication.

The term "transceiver" in the context of the paragraph immediately above will be understood to mean "signal transceiver" used for transmission of the level and/or alignment, and will be understood by the skilled addressee to be different to any ultrasonic transceiver which may be comprised within a distance sensor and used for distance measurement.

An ultrasonic transceiver may be comprised within a distance sensor such as an ultrasonic distance sensor or an ultrasonic level sensing transducer, which use an ultrasonic transmitter for transmitting an ultrasonic wave and an ultrasonic receiver for receiver a returned (echo) wave before computing the level using the time taken for the "echo" to be received along with the speed of sound in the medium used.

In some applications it may be required for level measurements to be provided in remote and hard-to-reach locations. As such, remote telemetry of the level and/or alignment is preferably provided by some embodiments of the present invention comprising a transceiver.

Communication of the alignment and/or level can preferably be provided by a long-distance wireless communication transceiver, such as a radio or mobile communication technology signal transceiver. Alternatively, communication of the level and/or alignment can preferably be provided by short-distance wireless communication technology such as, for example, BluetoothTM transceiver. Embodiments will be appreciated wherein any suitable wireless communication technology can be used for communication of the level and/or alignment by a transceiver to a receiver.

Embodiments will be appreciated wherein one or more output members comprise both a display member and a transceiver.

Preferably the container comprises one selected from the group: open channel; sewer overflow; storm drain; storage tank; a pipeline; a weir; a grain silo. Preferably the container is a utilities management pipeline.

The term "container" in the context of the present invention will be understood by the skilled addressee to mean any enclosed, open, sealed and/or openable container arranged to accommodate a content.

In embodiments wherein the container comprises a weir, the content is preferably a fluid.

Measurement of the level of said fluid in such embodiments is preferably arranged to inform of other corresponding measurands. Preferably, for example, said level is proportional to flow rate and/or volume of fluid over the weir.

Applications of the apparatus of the present invention preferably include utilities management and monitoring, but embodiments will be appreciated that are suitable for any appropriate application requiring level sensing. Additional example applications may include agriculture; fuel storage; recycling; and/or waste management.

Preferably the alignment detecting member comprises an accelerometer. Preferably the accelerometer is a 6-axis accelerometer.

Accelerometers preferably provide a cheap and reliable means of providing accurate alignment/orientation information. Their suitable miniaturisation of modern accelerometers preferably enables their easy incorporation into a level sensing apparatus without requiring significant modification or alternation to the architecture of the apparatus. Embodiments will be appreciated wherein the alignment detecting member is not an accelerometer. In such embodiments, the alignment detecting member may comprise, for example, a gyro sensor; a compass sensor; a magnetometer; a magnet; a microelectromechanical system (MEMS); a nanoelectromechanical system (N EMS); a laser; a Hall effect sensor; a Hall effect switch; a motion sensor; and/or a proximity sensor. Embodiments will be appreciated wherein the alignment detecting member comprises any suitable means for detecting a change in an alignment of the apparatus.

Preferably the level sensing apparatus further comprises an alerting member arranged to provide an alert to a user, said alert being arranged to alert said user to a change in the alignment and/or the level.

Preferably the alerting member is arranged to provide an alarm. Preferably the alert and/or alarm comprises one selected from the group: a visible alert and/or alarm; an audible alert and/or alarm; a haptic alert and/or alarm; a vibratory alert and/or alarm; a digital alert and/or alarm. Preferably the alerting member is arranged to provide an alert and/or alarm to the transceiver for communication to a receiver. In such embodiments, the transceiver is arranged to transmit the alert and/or alarm. Preferably the alert and/or alarm is arranged to alert a user to an atypical alignment/orientation, and/or an atypical level.

Preferably the level sensing apparatus further comprises a locating member arranged to detect a location of the level sensing apparatus, and wherein the one or more output nodes are further arranged to output the location. In embodiments comprising an alerting member, preferably the alerting member is further arranged to alert a user to a change to the location.

There are a number of events, such as flooding, seismic events or human intervention such as ragging, which may cause a level sensing apparatus to dislodge and/or move location within a container. It is therefore preferable that embodiments of the present invention are arranged to provide a location of the level sensing apparatus. The detecting of the location of the level sensing apparatus by the locating member preferably also enables easier inspection, maintenance and repair of a level sensing apparatus, even in instances wherein there is no change to the location. Preferably the location enables easier interpretation of the level and/or the alignment, in order to determine reliability of the level and/or the alignment provided by the apparatus.

Preferably the content is one selected from the group: waste water; fresh water; treated water; agricultural material; agricultural waste; grain; feed; fuel; slurry; sewage.

Embodiments will be appreciated wherein the content comprises a fluid. Embodiments will be appreciated wherein the content comprises any material suitable to be contained within and/or transported along a container.

In accordance with a second aspect of the present application, there is provided a level sensing system comprising a level sensing apparatus of the first aspect of the present invention, wherein the system further comprises a receiver arranged to receive the level, the alignment and/or the location, the receiver further comprising a storage member arranged to store the level, the alignment and/or the location.

The ability for the apparatus of the first aspect of the present invention, and system of the second aspect of the present invention, to allow a user to remotely cross reference the apparatus or sensor alignment and/or location with potentially suspect level data provided by the apparatus would preferably have real-world benefits, such as improving confidence in the technology, and reducing the requirements for skilled labour and cost. The ability of said apparatus or system to record the apparatus or sensor alignment and/or location, and then correlate it with information provided by on-site visits performed by technicians would also preferably help during maintenance contracts.

Detailed Description

Specific embodiments will now be described by way of example only, and with reference to the accompanying drawings, in which: FIG. 1 shows a sectional view of a pipe having a level sensing apparatus affixed thereto, the level sensing apparatus being in accordance with a first aspect of the present invention; FIG. 2 shows a schematic view of a level sensing system in accordance with the second aspect of the present invention.

Referring to FIG.1, there is provided a level sensing apparatus 10 comprising a housing 12 affixed to an interior surface of a pipe 14 by a rigid connecting frame 16. The level sensing apparatus 10 is suspended in an affixed position within the interior of the pipe 14 above a fluid 18 located within said pipe 14. The level sensing apparatus 12 comprises a distance sensor 20 positioned on a lowermost surface of the level sensing apparatus 12 and aligned with an uppermost surface 22 of the fluid 18. The level sensing apparatus 12 further comprises an alignment detecting member 23 located on the interior of the level sensing apparatus 12, and a display member 24 positioned on an uppermost exterior surface of the level sensing apparatus 12. The level sensing apparatus 12 further comprises a transceiver 26 connected to the housing 12 by a wire 28.

The distance sensor 20 and the alignment detecting member 23 are in digital communication with the display member 24 and the transceiver 26. The distance sensor 20 in the embodiment shown is an ultrasonic level sensing transducer arranged to transmit an ultrasonic wave signal toward the surface 22 of the fluid 18. The surface 22 of the fluid 18 reflects the ultrasonic wave signal back toward the ultrasonic level sensing transducer 20 which receives the reflected wave signal. The distance between the ultrasonic level sensing transducer 20 and the surface 22 of the fluid 18 is then calculated by a processor comprised with the level sensing apparatus 12. The calculation is performed using the duration of time between the transmission of the ultrasonic wave signal and the receipt of the reflected ultrasonic wave signal, together with the speed of sound in air, and is used to determine the level of the fluid.

In the level sensing apparatus 10 of the embodiment shown, the alignment detecting member 23 is an accelerometer. In order to provide a continued accurate and comparable calculation of the level of the fluid 18 using the distance sensor 20 over time, the alignment of the level sensing apparatus 12 must remain the same. The accelerometer 23 is used to detect a change in alignment of the level sensing apparatus 10. Upon a detection of a change to the alignment of the level sensing apparatus 10 by a processor in digital communication with the accelerometer 23, the processor provides an alert to the display member 24 and the transceiver 26. During installation of the level sensing apparatus 10, an engineer may use the display member 24 as a direct feedback mechanism to alert the engineer to the optimum orientation/alignment. As such, the installation of the level sensing apparatus 10 of the embodiment shown according to the first aspect of the present invention is made easier, and does not require skilled use of equipment or installation tools unlike comparable existing technology.

In use, the transceiver 26 is arranged to transmit the level data and the alignment data to a remote receiver (not shown).

The alignment of the level sensing apparatus 10 may be altered in use by, for example, debris within a pipe, flood events, ragging or human intervention such as during inspection, jetting, maintenance or during repair of the pipe or apparatus. It may be the case that after such an event, the distance (indicating the depth or level of said fluid) that is reported or displayed by said level sensing apparatus 10 is no longer accurate. In some cases the orientation or alignment may be altered in use such that the distance that is reported or displayed by the level sensing apparatus 10 is plausible, and therefore, in level sensing apparatus not in accordance with the present invention, would otherwise misinform level monitoring personnel of the fluid level. The alignment member of the embodiment shown, in accordance with the present invention, ensures that level monitoring personnel are informed of any change to the alignment and therefore reliability of any level sensing. The monitoring personnel are therefore provided with the option to ignore said level data or reduce the impact of said level data on any conclusions drawn from an array of said level sensing apparatuses.

Referring to FIG. 2, a level monitoring system 30 in accordance with the second aspect is shown, comprising a plurality of level monitoring apparatuses 10 in accordance with the first aspect of the present invention and as described in relation to FIG. 1. Said level monitoring apparatuses 10 are distributed about a utilities management pipeline network 32 and are arranged to communicate a level and/or an alignment to a remote receiver 34 using a transceiver. In the embodiment, the remote receiver 34 is a server within a control room wherein level monitoring personnel monitor the level and alignment detected and communicated by said apparatuses 10. The server 34 preferably comprises a processor arranged to process said level and alignment and is preferably arranged to calculate a use said level and alignment to calculate a change in said level and/or said alignment over time.

In the embodiments shown, the level sensing apparatus does not comprise a location detecting member. Embodiments will be appreciated wherein the level sensing apparatus further comprises a location detecting member arranged to detect a location of the level sensing apparatus and communicate the location to the transceiver for remote transmission of said location to a remote receiver. In such embodiments, should said level sensing apparatus become detached from the interior of a container and change location, a processor receiving said location may be arranged to detect said change in location and provide an alert. Said detachment may be due to, for example, debris within a pipe, flood events, ragging or human intervention such as during inspection, jetting, maintenance or during repair of the pipe or apparatus. In such circumstances, the location detecting member preferably improves the ease of locating said level sensing apparatus.

It will be appreciated that the above described embodiments are given by way of example only and that various modifications thereto may be made without departing from the scope of the invention as defined in the appended claims. For example, the embodiments described relate to a fluid within a container taking the form of a pipeline. Additional embodiments will be appreciated wherein the container is an open channel. Additional further embodiments will be appreciated wherein the content is fuel, which may be located in a fuel tank. Additional further embodiments will be appreciated wherein the content is not a fluid, and is, for example, grain in a grain silo. Further embodiments will be appreciated wherein the distance sensor is positioned within or below the surface of said contents and may in such embodiments be oriented toward a surface of said contents. In the example embodiments described, the distance sensor is an ultrasonic distance sensor. Additional embodiments will be appreciated wherein the distance sensor is not an ultrasonic distance sensor, and may for example comprise a laser, a radar and/or any suitable means for detecting a level of the content using a distance measurand. In the example embodiments described, the alignment detecting member is an accelerometer. Additional embodiments will be appreciated wherein the alignment detecting member is not an accelerometer, and may for example comprise a gyro, a compass and/or any suitable means for detecting a change to an alignment of the apparatus.

Claims

CLAIMSA level sensing apparatus comprising a distance sensor arranged to detect a level of a content in a container, wherein the level sensing apparatus further comprises an alignment detecting member, the alignment detecting member arranged to detect an alignment of the distance sensor; and one or more output nodes arranged to output the level and/or the alignment to one or more output members.
A level sensing apparatus as claimed in claim 1, wherein the level sensing apparatus comprises said one or more output members.
3. A level sensing apparatus as claimed in claim 1 or claim 2, wherein the distance sensor is an ultrasonic distance sensor.
A level sensing apparatus as claimed in claim 3, wherein the ultrasonic distance sensor comprises an ultrasonic transducer.
5. A level sensing apparatus as claimed in any one of claims 1 to 4, wherein the one or more output members comprise a display member arranged to display the level and/or the alignment to a user.
6. A level sensing apparatus as claimed in any one of the preceding claims, wherein the one or more output members comprise a transceiver arranged to transmit the level and/or the alignment to a receiver.
7. A level sensing apparatus as claimed in claim 6, wherein the transceiver is arranged to transmit the level and/or alignment to the receiver using a communication technology selected from the group: wired communication; wireless communication; short-range wireless communication; long-range wireless communication; radio signal; mobile communication technology; optical fibre communication.
8. A level sensing apparatus as claimed in any one of the preceding claims, wherein the container comprises one selected from the group: open channel; sewer overflow; storm drain; storage tank; a pipeline; a weir; a grain silo.
9. A level sensing apparatus as claimed in claim 8, wherein the pipeline is a utilities management pipeline.
10. A level sensing apparatus as claimed in any one of the preceding claims, wherein the alignment detecting member comprises an accelerometer.
11. A level sensing apparatus as claimed in claim 10, wherein the accelerometer is a 6-axis accelerometer.
12. A level sensing apparatus as claimed in any one of the preceding claims, wherein the level sensing apparatus further comprises an alerting member arranged to provide an alert to a user, said alert being arranged to alert said user to a change in the alignment and/or the level.
13. A level sensing apparatus as claimed in claim 12, wherein the alert comprises one selected from the group: a visible alert; an audible alert; a haptic alert; a vibratory alert; a digital alert.
14. A level sensing apparatus as claimed in any one of the preceding claims, wherein the level sensing apparatus further comprises a locating member arranged to detect a location of the level sensing apparatus, and wherein the one or more output nodes are further arranged to output the location.
15. A level sensing apparatus as claimed in claim 14, comprising the features of claim 12, and wherein the alerting member is further arranged to alert a user to a change to the location.
16. A level sensing apparatus as claimed in any one of the preceding claims, wherein the content is one selected from the group: waste water; fresh water; treated water; agricultural material; agricultural waste; grain; feed; fuel; slurry; sewage.
17. A level sensing system comprising a level sensing apparatus as claimed in any one of claims 1 to 16, wherein the system further comprises a receiver arranged to receive the level, the alignment and/or the location, the receiver further comprising a storage member arranged to store the level, the alignment and/or the location.