Sensor and method for ullage level and flow detection

Abstract

A device is provided for detecting the ullage level and flow in a vessel by detecting the presence of a solid or liquid material in proximity to a microwave detector. The device may be mounted to the side of the vessel or suspended inside the vessel so as to bring the microwave sensor into proximity with the surface of the contents of the vessel. A microwave bridge circuit may be used to detect a change in either the amplitude or phase of a signal reflected by the material within the vessel compared to a reference signal tuned to either the presence or absence of the anticipated solid or liquid material. In one embodiment, the reflected material signal is compared to the signal from a sample chamber containing the material to be detected. The device can reliably detect the level of multiple interfaces for various materials having distinct electric or magnetic properties.

What is claimed is: 
     
       1. A sensor for detecting the movement characteristics of material in a container or conduit, comprising: microwave oscillator means for generating a constant propagated microwave in a frequency range of from 1 to 20 gigahertz;   microwave bridge circuit means for dividing microwave into a measurement microwave and a reference microwave;   first guide means for injecting the measurement microwave through a portion of the container substantially transparent to the propagated microwave frequency and for returning a reflected measurement microwave to the microwave bridge circuit means indicative of the reflection coefficient at the boundary layer of the transparent portion, the coefficient being significantly altered by one of the presence, the absence and the movement of the material at the level of the first guide means;   second guide means for transmitting the reference wave from the microwave bridge circuit means and for returning a reflected reference wave to the microwave bridge circuit means;   reference wave altering means for altering the reflected reference wave to correspond in amplitude and phase to the reflected measurement microwave as altered by the presence, absence or movement of the material at the level of the first guide means;   the microwave bridge circuit means receiving the reflected measurement and reference waves and producing a differentiation signal indicative of a difference in magnitude and phase between the waves;   detector means for generating an output indicative of the magnitude of the differentiation signal; and   comparator means for comparing the magnitude of the detector means output to a preselected signal magnitude and for providing an actuation signal indicative of the presence, absence or movement of the material at the level of the first guide means.   
     
     
       2. The sensor as defined in claim 1, wherein the reference wave altering means comprises: a sample chamber containing a quantity of the material in the container and positioned at an end of the second guide means, the reflected reference microwave being indicative of the reflection coefficient at the boundary layer of the sample chamber.   
     
     
       3. The sensor as defined in claim 1, wherein the reference wave altering means comprises: a resistive tuning means adjustably positionable with respect to the second guide means for selectively altering the magnitude of the reflected reference wave to equal the magnitude of the reflected measurement wave; and   two or more reactive tuning elements adjustably positionable with respect to the second guide means for selectively altering the phase of the reflected reference wave to equal the phase of the reflected measurement wave.   
     
     
       4. The sensor as defined in claim 3, wherein the output of the detector means is a DC signal whose magnitude is proportional to the magnitude of the difference in amplitude and phase between the reflected measurement and reference waves. 
     
     
       5. The sensor as defined in claim 1, wherein the transparent portion of the container is a dielectric tank wall. 
     
     
       6. The sensor as defined in claim 1, wherein the axis of the first and second guide means are aligned, and the second guide means transmits the reference wave to the reference wave altering means in a direction opposite the transparent portion of the container. 
     
     
       7. The sensor as defined in claim 1, further comprising: amplifying means for increasing the magnitude of the output from the detector means; and   amplifying adjustment means for selectively adjusting the gain of the amplifying means.   
     
     
       8. The sensor as defined in claim 1, further comprising: time delay means for receiving the actuation signal and outputting a control signal when the actuation signal is maintained for at least a selected time period.   
     
     
       9. The sensor as defined in claim 1, wherein the interior cross-section of the first guide means is substantially identical to the interior cross-section of the second guide means. 
     
     
       10. The sensor as defined in claim 1, wherein the microwave bridge circuit outputs the differential signal in a direction substantially normal to the axis of the first guide means. 
     
     
       11. A sensor for detecting the movement characteristics of material in a container, comprising: microwave oscillator means for generating a constant propagated microwave in a frequency range of from 1 to 20 gigahertz;   microwave bridge circuit means for dividing the propagated microwave into a measurement microwave and a reference microwave;   first guide means for injecting the measurement microwave through a portion of the container substantially transparent to the propagated microwave frequency and for returning a reflected measurement microwave to the microwave bridge circuit means indicative of the reflection coefficient at the boundary layer of the transparent portion, the coefficient being significantly altered by the presence compared to the absence of the material at the level of the first guide means;   second guide means for transmitting the reference wave from the microwave bridge circuit means and for returning a reflected reference wave to the microwave bridge circuit means;   reference wave altering means for altering the reflected reference wave to correspond to the reflected measurement microwave as altered by the presence or absence of the material at the level of the first guide means;   the microwave bridge circuit means receiving the reflected measurement and reference waves and producing a differentiation signal indicative of a difference between the waves;   detector means for generating an output indicative of the magnitude of the differentiation signal; and   comparator means for comparing the magnitude of the detector means output to a preselected signal magnitude and for providing an actuation signal indicative of the presence or absence of the material at the level of the first guide means.   
     
     
       12. The sensor as defined in claim 11, wherein the reference wave altering means alters the amplitude and phase of the reflected reference microwave to correspond to the amplitude and phase of the reflected measurement microwave. 
     
     
       13. The sensor as defined in claim 12, wherein the output of the detector means is a DC signal whose magnitude is proportional to the magnitude of the difference in amplitude and phase between the reflected measurement and reference waves. 
     
     
       14. The sensor as defined in claim 11, wherein the reference wave altering means comprises: a resistive tuning means adjustably positionable with respect to the second guide means for selectively altering the magnitude of the reflected reference wave to equal the magnitude of the reflected measurement wave; and   two or more reactive tuning elements adjustably positionable with respect to the second guide means for selectively altering the phase of the reflected reference wave to equal the phase of the reflected reference measurement wave.   
     
     
       15. The sensor as defined in claim 11, further comprising: amplifying means for increasing the magnitude of the output from the detector means;   amplifying adjustment means for selectively adjusting the gain of the amplifying means; and   time delay means for receiving the actuation signal and outputting a control signal when the actuation signal is maintained for at least a selected time period.   
     
     
       16. A method for detecting the movement characteristics of material in a conduit or container, comprising: generating a constant propagated microwave in a frequency range of from 1 to 20 gigahertz;   separating the propagating microwave into a measurement microwave and a reference microwave;   injecting the measurement microwave through a portion of the container substantially transparent to the propagated microwave frequency and returning a reflected measurement microwave indicative of the reflection coefficient at the boundary layer of the transparent portion, the coefficient being significantly altered by the presence compared to the absence of the material at the boundary layer;   transmitting the reference wave and returning a reflected reference wave;   selectively altering the reflected reference wave to correspond to the reflected measurement microwave as altered by the presence or absence of the material at the boundary layer;   receiving the reflected measurement and reference waves and outputting a differentiation signal indicative of a difference between the waves;   generating an output indicative of the magnitude of the differentiation signal; and   comparing the magnitude of the output to a preselected magnitude and providing an actuation signal indicative of the presence or absence of the material of the level at the boundary layer.   
     
     
       17. The method as defined in claim 16, wherein the amplitude and phase of the reflected reference microwave is selectively tuned to the amplitude and phase of reflected measurement microwave. 
     
     
       18. The method as defined in claim 17, wherein the output indicative of the magnitude of the differential signal is a DC output proportional to the difference in amplitude and phase between the reflected measurement and reference waves. 
     
     
       19. The method as defined in claim 16, wherein the step of selectively altering the reflected reference wave comprises subjecting the reference wave to the same material as the material in the container. 
     
     
       20. The method as defined in claim 16, wherein the step of selectively altering the reflected reference wave comprises: adjustably positioning a tuning element to selectively alter the magnitude of the reflected reference wave to equal the magnitude of the reflected measurement wave; and   adjustably positioning another tuning element to selectively alter the phase of the reflected reference wave to equal the phase of the reflected measurement wave.   
     
     
       21. A method for detecting the movement characteristics of material in a conduit or container, comprising: (a) generating a wave having a frequency from 1 to 20 gigahertz;   (b) separating the wave into a measurement wave and a standard wave;   (c) transmitting and injecting the measurement wave into the container for impacting the available material and for returning a reflected measurement wave indicative of the reflection coefficient at the point of impact, the characteristics of the reflection coefficient being altered by the movement characteristics of the material;   (d) transmitting and altering the standard wave for producing a reflected standard wave having an amplitude and phase corresponding to an amplitude and phase associated with the measurement wave;   (e) combining the reflected measurement wave with the reflected standard wave for either constructively enhancing or destructively reducing the combined waveform for generating a combined wave;   (f) analyzing the combined wave to determine the presence of, absence of, or motion of the material in the container, and   (g) generating an actuation signal indicative of the presence of, absence of, or motion of the material in the container.   
     
     
       22. The method as defined in claim 21 wherein the step of transmitting and altering the standard wave comprises altering the standard wave with tuning elements for producing a reflected standard wave having an amplitude and phase equal to the amplitude and phase of the reflected measurement wave when impacting the material whose presence or absence is sought to be determined. 
     
     
       23. The method as defined in claim 21 wherein the step of analyzing the combined wave comprises: (a) generating a first output by differentiating between the magnitude of the combined wave and a comparator threshold such that the comparator output is either low or high indicating the magnitude of the combined wave is either below or above the comparator threshold, respectively, and   (a) generating a second output from the first output for activating a relay which drives lights, alarms, pumps and the like by ramping down a low first output and by ramping up a high first output whereby extraneous portions of the first output caused by splashing, sloshing and the like are selectively purged from the resultant second output.   
     
     
       24. The method as defined in claim 21 wherein the step of analyzing the combined wave comprises: (a) generating a bipolar signal, from the combined wave by taking the difference between a present instantaneous sample of the combined wave and a delayed instantaneous sample of the combined wave whereby no change in the amplitude of the instantaneous samples creates a zero bipolar signal; and   (b) generating a unipolar signal from the bipolar signal whereby the magnitude of the unipolar signal is equal to the absolute value of the bipolar signal.   
     
     
       25. The method as defined in claim 24 further comprising the step of amplifying the combined wave for enhancing changes caused by the reflection coefficient. 
     
     
       26. The method as defined in claim 24 wherein the step of generating a unipolar signal comprises: (a) generating a dense unipolar signal, and   (b) generating a sparse unipolar signal whereby the dense unipolar signal indicates a dynamic flow condition, the sparse unipolar signal indicates intermittent flow conditions, and the absence of any unipolar signal indicates the absence of flow.   
     
     
       27. A sensor for detecting the movement characteristics of material in a container or conduit, comprising: (a) an oscillator for generating a constant propagated microwave in a frequency range of from 1 to 20 gigahertz;   (b) a bridge for dividing the microwave into a measurement microwave, a reference microwave and a combined microwave, said bridge comprising: (1) a medial waveguide for accepting the microwave from said oscillator and for egressing the measurement microwave and the reference microwave,   (2) a measurement waveguide, for accepting the measurement microwave from said medial waveguide and for impinging the measurement microwave on, for passage through, a portion of the container substantially pellucid to the microwave frequency and for returning a reflected measurement microwave indicative of the reflection coefficient at the boundary layer of the pellucid portion, the reflection coefficient being significantly altered by the presence, the absence and the movement of the material;   (3) a reference waveguide, for accepting the reference microwave from said medial waveguide and for returning a reflected reference wave;   (4) an interference waveguide for accepting the reflected measurement microwave and the reflected reference microwave for creating a combined reflected microwave characteristic of the interference caused by the combination of the reflected measurement microwave and the reflected reference microwave,     (c) a reference wave altering means in operative association with said reference waveguide for modifying the reference wave to correspond in amplitude and phase to the reflected measurement microwave as altered by the presence, absence or movement of the material at the level of the first guide means;   (d) detector means for receiving said combined reflected microwave and for generating an output indicative of said combined reflected microwave; and   (e) comparator means for comparing the magnitude of the detector means output to a preselected signal magnitude and for providing an actuation signal indicative of the presence, absence or movement of the material at the level of the first guide means.   
     
     
       28. A sensor for detecting the movement characteristics of material in a container or conduit as defined in claim 27 wherein said measurement waveguide and said reference waveguide are of equal length. .Iadd. 
     
     
       29.  A sensor for detecting movement, and one of presence and absence, of material comprising: (a) an oscillator for generating microwaves;   (b) microwave bridge means for dividing the generated microwaves into measurement microwaves which engage the material and reference microwaves which engage a tuning means for controlling the amplitude and phase of the reflected reference microwaves, and for receiving reflected microwaves after engagement with the material and tuning means such that the reflected microwaves combine to form a reflected differential signal, which differential signal is nil or zero if the impedance at the material and tuning means is substantially equal,   (c) means for processing the differential signal from said microwave bridge means for determining movement, and one of presence and absence, of material as indicated by a change in the differential signal, said means for processing comprising (1) means for receiving the differential signal from said microwave bridge means;   (2) means for comparing the change in the differential signal amplitude with respect to time for generating a difference signal,   (3) means for generating an output proportional to variations in the difference signal,   (4) means for accepting the proportional output and generating a primary control signal,   (5) means responsive to the differential signal, the difference signal, a reference voltage and a drive signal for producing an action signal, and     (d) means for accepting the action signal and the primary control signal and for generating the drive signal. .Iaddend. .Iadd.   
     
     
       30.  A method for detecting movement, and one of presence and absence, of material comprising the steps of: (a) generating microwaves;   (b) dividing the generated microwaves into measurement microwaves and reference microwaves,   (c) reflecting the measurement microwaves from the material and the reference microwaves from a tuning means for controlling the amplitude and phase of the reflected reference microwaves,   (d) impressing the reflected measurement microwaves with the reflected reference microwaves to render a differential signal; and   (e) processing the differential signal for determining movement, and one of presence and absence, of material indicated by a change in the differential signal, said step of processing the differential signal further comprising the steps of: (1) receiving the differential signal;   (2) comparing the change in the differential signal amplitude with respect to time for generating a difference signal,   (3) generating an output proportional to variations in the difference signal,   (4) generating a primary control signal from the proportional output,   (5) generating an action signal responsive to the differential signal, the difference signal, a reference voltage and a drive signal, and     (f) generating, from the action signal and the primary control signal, the drive signal representative of movement, and one of presence and absence, of material for controlling other processing equipment in response to the flow condition of the material. .Iaddend.