Ultrasonic monitoring technique for containers and apparatus to carry it out

• US 6,234,023 B1
• Filed: 10/19/1998
• Issued: 05/22/2001
• Est. Priority Date: 11/09/1995
• Status: Expired due to Fees

• Current Assignee: M & A Packaging Services Limited, University of Warwick
• Original Assignee: M & A Packaging Services Limited
• Inventors: Edwards, Christopher, Collins, Andrew P., Dixon, Steven M, Palmer, Stuart B
• Primary Examiner(s): Williams, Hezron
• Assistant Examiner(s): MILLER, ROSE MARY
• Application Number:
  US09/068,244
• Time in Patent Office: 946 Days
• Field of Search: 732/90.V, 736/43, 735/98, 735/97, 209/590, 209/524, 209/529
• US Class Current: 73/597
• CPC Class Codes: B67C 3/284 using non-liquid contact sensing means B67C3/283 takes precedence
• CPC Class Codes: G01F 23/2962 Measuring transit time of reflected waves
• CPC Class Codes: G01F 23/2968 Transducers specially adapted for acoustic level indicators
• CPC Class Codes: G01N 2291/011 Velocity or travel time
• CPC Class Codes: G01N 2291/02836 Flow rate, liquid level
• CPC Class Codes: G01N 2291/02854 Length, thickness
• CPC Class Codes: G01N 2291/0421 Longitudinal waves
• CPC Class Codes: G01N 2291/0422 Shear waves, transverse waves, horizontally polarised waves
• CPC Class Codes: G01N 2291/048 Transmission, i.e. analysed material between transmitter and receiver
• CPC Class Codes: G01N 2291/102 one emitter, one receiver
• CPC Class Codes: G01N 29/2418 using optoacoustic interaction with the material, e.g. laser radiation, photoacoustics photoacoustic cells G01N21/1702; measuring characteristics of vibrations by using radiation-sensitive means G01H9/00; acousto-optical conversion techniques for short-range imaging G01S15/8965; sound-producing devices using laser bundle G10K15/046

Abstract

The invention provides an apparatus and method for fill level monitoring in which the height of contents in a container (10) is monitored. The apparatus comprises an ultrasound reciever (30) and signal processing means (50-56) adapted to receive signals from the receiver, the arrangement being such that the signal processing means (50-56) identifies a first signal (32), in use, which is representative of a wavefront (26) transmitted through the contents of the container (10) independently of the height of the contents in the container (10), and a second signal (34) that is representative of a wavefront (24) that is reflected from the interface (22) between the surface of the contents in the container (10) and the environment above the contents, and in which the signal processing means (50-56) uses the difference in travel time for the two wavefronts (24, 26) to provide a measurement of the level of the contents in the container (10). A plasma generation system comprising a pulsed laser (99) and a target (101) in front of the container (102) is also disclosed, the plasma (103) creating ultrasound in the container (102).

Claims

1. A fill level monitoring apparatus adapted to monitor the height of contents in a container, comprising ultrasound generation means, an ultrasonic receiver and signal processing means adapted to receive signals from the receiver, the arrangement being such that the signal processing means identifies a first signal which is representative of a first ultrasonic wave which has travelled directly though the contents of the container to the receiver without reflection independently of the height of the contents in the container, and a second signal that is representative of a second ultrasonic wave that has been reflected from the interface between the upper surface of the contents in the container and the environment above the contents, and in which the signal processing means uses the difference in transit times for the two waves to provide an indication of the level of the contents in the container, and in which the first and second waves are part of the same ultrasonic wavefront in three dimensions.

2. A fill level monitoring apparatus according to claim 1, in which the ultrasound receiver is couplant free.

3. A fill level monitoring apparatus according to claim 1, in which the apparatus includes a broadband ultrasound receiver.

4. A fill level monitoring apparatus according to claim 3, in which the broadband ultrasound receiver can detect from low frequency to above 1 MHz.

5. A fill level monitoring apparatus according to claim 1, in which the receiver is an EMAT.

6. A fill level monitoring apparatus according to claim 5, in which the EMAT is polarised, to give maximum sensitivity to top surface reflections of ultrasound from the upper surface of the contents of the container.

7. A fill level monitoring apparatus according to claim 1, in which the receiver detects ultrasound from only a localised region in height of the container.

8. A fill monitoring apparatus according to claim 7 in which the container includes an exterior surface and the receiver detects ultrasound over a localised region of the container surface restricted to a vertical range of 4 mm or less.

9. A fill level monitoring apparatus according to claim 1, in which the apparatus is arranged such that the ultrasound receiver is disposed to a side of a container.

10. A fill level monitoring apparatus according to claim 1, in which the receiver is not more than 10 mm from the surface of the container when the ultrasound waves that generate the first and second signals are detected.

11. A fill level monitoring apparatus according to claim 1 in which the ultrasound generation means is adapted to generate simultaneously the ultrasound wave(s) which give rise to the first and second signals.

12. A fill level monitoring apparatus according to claim 1 in which the ultrasound generation means is adapted to generate at the same location on the container the ultrasound wave(s) which when detected generate the first and second signal.

13. A fill level monitoring apparatus according to claim 1 in which the ultrasound generation means is adapted to generate the ultrasound waves in a localised region in height of the container.

14. A fill level monitoring apparatus according to claim 1, in which the ultrasound generation means includes a laser.

15. A fill level monitoring apparatus according to claim 1 in which the ultrasound generation means is couplant free.

16. A fill level monitoring apparatus according to claim 1 in which the ultrasound generation means is capable of generating a broadband ultrasonic wave.

17. A fill level monitoring apparatus according to claim 1 in which the apparatus is arranged such that the ultrasound generation means is disposed to the side of the container.

18. A fill level monitoring apparatus according to claim 1 in which the receiver and generation means are on opposite sides of the container.

19. A fill level monitoring apparatus according to claim 1 in which when viewed from above the container the receiver and the generation means are at an angle away from the 180°

straight-through configuration.

20. A fill level monitoring apparatus according to claim 1 in which the receiver and the generation means are at substantially the same height relative to the container.

21. A fill level monitoring apparatus according to claim 1 in which the receiver is at a different height to that of the generation means relative to the container.

22. A fill level monitoring apparatus according to claim 1 in which the container is moving during the transmission of the ultrasound waves that create the first signal, the second signal, or both signals.

23. A fill level monitoring apparatus according to claim 1 which is used with a container that is metallic or has a metal region.

24. A fill level monitoring apparatus according to claim 1, in which there is a feedback mechanism whereby the apparatus can feed back signals, derived from the first and second signals, to control apparatus for subsequent use in controlling the filling operation or filling apparatus.

25. A fill level monitoring apparatus according to claim 1 in which the apparatus has an electronic signal filter.

26. A fill level monitoring apparatus according to claim 1, in which the apparatus has a signal amplifier, which is tuned to the same band of frequencies as the receiver.

27. A container filling line comprising containing filling means adapted to deliver contents to a container, control means controlling the operation of the container filling means and fill-level monitoring apparatus adapted to monitor the height of content in a container, comprising an ultrasonic generation means, an ultrasound receiver and signal processing means adapted to receive signals from the receiver, the arrangement being such that the signal processing means identifies a first signal which is representative of a first ultrasonic wave which has been transmitted through the contents of the container independently of the height of the contents in the container directly from the ultrasonic generation means to the receiver, and a second signal that is representative of the second ultrasonic wave that has been reflected from the interface between the surface of the contents in the container and the environment above the contents, and in which the signal processing means uses the difference in transit times for the two waves to provide an indication of the level of the contents in the container.

28. A method of monitoring the fill level of contents in a container comprising generating ultrasound waves in the container, detecting a straight through ultrasound wave, detecting a top surface reflected wave from the top surface of the contents of the container, and measuring the time difference between the detection of the two waves in order to obtain an indication of the level of the contents in the container.

29. A method of monitoring the fill level of contents in a container according to claim 28 comprising using signal processing means to receive and identify a first signal which is representative of the straight through wave, and using the signal processing means to receive and identify a second signal which is representative of the top surface reflected wave, and wherein the signal processing means uses the arrival time of the first signal, and the pathlength of the straight through wave in the contents which is known from the dimensions of the container, in conjunction with the time difference between receipt of the first signal and receipt of the second signal to measure the height of the contents.

30. A method of monitoring the fill level of contents in a container comprising generating a first ultrasonic wave in the container and measuring its transit time to travel a first path directly through the contents of the container without reflection, from an ultrasonic generation means to an ultrasonic receiver that is independent of the level of contents in the container;

generating a second ultrasonic wave in the container and measuring its transit time to travel a second path directly through the contents of the container that has a reflection from the surface of the contents of the container; and

using the difference in transit time to evaluate the height to which the container is filled.

31. A fill level monitoring apparatus adapted to monitor the height of contents in a container, comprising an ultrasonic generator, an ultrasound receiver, and signal processing means adapted to receive signals from the receiver, the arrangement being such that the signal processing means identifies a first signal which is representative of a first ultrasonic wave which has been transmitted through the contents of the container independently of the height of the contents in the container, and a second signal that is representative of a second ultrasonic wave that has been reflected from the interface between the upper surface of the contents of the container and the environment above the contents, wherein the ultrasound generator is adapted to generate simultaneously the first and second ultrasonic waves and in which the signal processing means uses the difference in transit times for the two waves to provide an indication of the level of the contents in the container.

32. A fill level monitoring apparatus adapted to monitor the height of contents in a container, comprising an ultrasonic generator, an ultrasound receiver and signal processing means adapted to receive signals from the receiver, the arrangement being such that the signal processing means identifies a first signal which is representative of a first ultrasonic wave which has been transmitted through the contents of the container independently of the height of the contents in the container, and a second signal that is representative of a second ultrasonic wave that has been reflected from the interface between the upper surface of the contents of the container and the environment above the contents, in which the ultrasound generator is adapted to generate the ultrasound waves in a localized region in height of the container.

33. A fill line monitoring apparatus comprising container filling means adapted to deliver contents to a container, control means controlling the operation of the container filling means, an ultrasound generator, an ultrasound receiver and signal processing means adapted to receive signals from the receiver, the arrangement being such that the signal processing means identifies a first signal which is representative of a first ultrasonic wave which has been transmitted through the contents of the container independently of the height of the contents in the container, and a second signal that is representative of a second ultrasonic wave that has been reflected from the interface between the upper surface of the contents of the container, and in which the first and second waves are parts of the same ultrasonic wavefront in three dimensions.

34. A container filling line according according to claim 33 in which the first signal is representative of a wave that has travelled directly to the receiver without reflection.

35. A container filling line comprising containing filling means adapted to deliver contents to a container, control means controlling the operation of the container filling means and fill-level monitoring apparatus adapted to monitor the height of content in a container, comprising an ultrasonic generation means, an ultrasound receiver and signal processing means adapted to receive signals from the receiver, the arrangement being such that the signal processing means identifies a first signal which is representative of a first ultrasonic wave which has been transmitted through the contents of the container independently of the height of the contents in the container, and a second signal that is representative of the second ultrasonic wave that has been reflected from the interface between the surface of the contents in the container and the environment above the contents, and in which the signal processing means detects ultrasound from only a localized region in height of the container and uses the difference in transit times for the two waves to provide an indication of the level of the contents in the container.