Nakagawa 2013
Nakagawa 2013
3, MARCH 2013
Abstract— A novel contactless method for measuring liquid is not high because the capacitance is strongly dependent on
level through an opaque container is proposed. A millimeter- the distance between the container and sensor. Optical sensors,
wave Doppler sensor is developed to “see” (i.e., sense) through a such as CCD cameras, can measure liquid level without having
target container and measure the liquid level on the basis of the
absorption of millimeter waves in liquid. One of the challenges is to contact the liquid by image processing [4]. However, to
to accurately measure liquid level (within sub-millimeter error) capture an image of the liquid surface, the container should
despite the inherently large beam diameter of the millimeter be transparent, or the optical sensors should be placed in
wave due to diffraction. A piezoelectric vibrator enables accurate the container. By using ultrasound sensors, liquid level can
measurement by reflecting a limited portion of the spread be calculated from the range between the sensor and liquid
beam and modulating it in frequency to distinguish it from the
other portion of the beam. A prototype measurement system is surface. However, these sensors cannot be used for sealed
fabricated and evaluated. The feasibility of our proposed method containers.
for clearly detecting an air-liquid interface concealed in an We propose a novel Contactless method for measuring
opaque container is confirmed experimentally. The nonlinearity liquid level through an opaque container, while an earlier
error of the measured liquid level is within ±0.5 mm. version was presented in Ref. [15]. A millimeter-wave sensor
Index Terms— Contactless sensing, frequency modulation, is used to “see” (i.e., sense) through a target container and
liquid-level measurement, millimeter wave. measure the liquid level without having to contact the liquid.
Millimeter-wave integrated circuits have recently experienced
I. I NTRODUCTION tremendous growth [16]. These circuits have become smaller,
more highly integrated, and less expensive. Moreover, mil-
Measurement Measurement the liquid level, but it must come in contact with the liquid.
unit unit A capacitive semi-cylindrical sensor mounted around a liquid
container can measure liquid level without having to contact
Switch the liquid [2], but its measurement accuracy is not high
Float Electrodes because the capacitance is strongly dependent on the distance
between the container and sensor.
Optical sensors can be used for liquid-level measurement
without having to contact the liquid (Fig. 1 (c)) [4]–[9]. An
Liquid Liquid optical camera and an image signal processor are used to
measure liquid level by detecting the edge of a captured image
and calculating the liquid level.
(a) (b) Ultrasound sensors can measure liquid level without having
to contact the liquid (Fig. 1 (d)) [12], [13]. This measurement
Ultrasound
method is based on the time-of-flight principle. The ultrasound
range meter sensors emit high-frequency (typically 20 to 200 kHz) acoustic
Camera
waves onto the liquid surface. The waves are reflected at
the liquid surface, and the sensor detects the echo from the
Reflection surface. The distance between the sensor and the liquid surface
is calculated from the time of flight, and the liquid level is
estimated. Because the method is based on the time-of-flight
Liquid Liquid principle, proper mounting of the sensor, which achieves “line
of sight” of the sensor to the target liquid surface, is required.
There are other types of sensors. For example, a pressure
(c) (d)
sensor immersed in a container can be used to measure
liquid level from liquid pressure. Load cells, based on a
Fig. 1. Liquid-level measurement methods. (a) Float type. (b) Capacitive strain gauge or piezoelectric sensor, are used for liquid weight
sensor. (c) Optical sensor. (d) Ultrasound sensor.
measurement; hence, for level measurement. Radar is useful
for measuring liquid level [14] by measuring the travel time
a novel method. Liquid-level measurement methods are clas- of a radio-frequency impulse transmitted and reflected from
sified into two types: contact, and Contactless. Contact-type the liquid surface.
liquid-level measurement methods include those for float-type Although there are a large variety of methods for liquid-
mechanical, electrical (capacitive and resistive), and pressure level measurement, these conventional methods are not
sensing. These methods are used to measure liquid level suitable for Contactless measurement of opaque containers.
directly by using a sensor that comes into contact with the Float-type, capacitive, and many other methods must come
liquid. On the other hand, Contactless methods, such as into contact with the target liquids. Ultrasound sensing and
those for optical and ultrasound sensing, measure liquid level radar methods are capable of measurement without having
without having to contact the liquid. Although Contactless to contact the liquid. However, the line of sight between the
methods are more complicated than contact methods, they sensor and liquid surface is essential; therefore, the sensor
are necessary for specific applications, such as measuring should be placed inside the container. Optical sensors can be
hazardous solutions and medical instruments. used to measure liquid level remotely; however, the container
Figure 1 shows four major types of liquid-level measure- should be transparent. Thus, optical sensors are not suitable for
ment methods. Float-type mechanical sensing is the simplest measuring the liquid level in opaque containers or containers
and most widely used (Fig. 1(a)). The sensors use a float with labels. Therefore, our target is Contactless liquid-level
as the primary sensing element and operate on the basis measurement through opaque containers.
of the buoyancy effect. Switching occurs as a result of the
movement of the float against a switch, which is usually set III. P ROPOSED L IQUID -L EVEL M EASUREMENT M ETHOD
to upper and/or lower limits. The sensor detects the switching
and measures the liquid level. Although a float-type sensor is A. Basic Consideration
simple and not expensive, it must contact the liquid because Our approach to achieving Contactless measurement is to
the sensor is put into the liquid. use millimeter waves. Millimeter waves can be used to “see”
Capacitive sensing is another well-known method for through non-transparent materials, such as plastics and paper.
contact-type liquid-level measurement (Fig. 1(b)) [1]. Therefore, millimeter-wave sensors do not require physical
A sensor, which consists of two electrodes, is inserted in a contact with the container or liquid, and the transmitter and
target liquid. The two electrodes are composed of a capacitor, receiver can be mounted at a distance from the liquid.
and the liquid acts as a dielectric medium. The capacitance While millimeter waves can penetrate plastic containers or
changes in response to the liquid level between the electrodes. paper labels, they are absorbed by some kinds of liquids, such
Then, the liquid level is calculated from the measured as liquid water, water solutions, and blood. The amount of
capacitance. The capacitive sensor can accurately measure absorption of an electromagnetic wave is characterized by the
928 IEEE SENSORS JOURNAL, VOL. 13, NO. 3, MARCH 2013
T arget T arget
container container
M illim eter M illim eter
w a ve w a ve V ibration in x direction
P ie zoe lectric
vibrator
M odulated
M illim eter-w ave M illim eter-w ave M illim eter-w ave w a ve
transm itter receiver D oppler sensor
Liquid Liquid
z z
x x
C ontroller
Fig. 2. Architecture of liquid-level measurement system with millimeter- Fig. 3. Architecture of proposed liquid-level measurement system with
wave transmitter and receiver. millimeter-wave Doppler sensor and piezoelectric vibrator.
Second
Millimeter-wave
attenuation constant, α, of the liquid, which is the real part of sensor chip PA lens
the propagation constant, γ, of the liquid, defined as
Antenna
γ = α + jβ = j ωμ(σ + j ωε) (1) Mixer
VLOC
VRF
where μ, ε, σ , and ω are permeability, permittivity, conductiv- Oscillator
First
ity, and angular frequency, respectively. Attenuation constant VIF LNA lens
differs from material to material; for example, according to
[19], α of liquid water for a millimeter wave is about 60 cm−1
FFT ADC
at 80-GHz frequency in the CGS system of units. This value Modulated-
corresponds to an attenuation length of about 0.2 mm. In other wave
power (P)
words, almost the entire millimeter wave is absorbed by liquid
water, and a millimeter wave with reasonable power cannot Fig. 4. Schematic of millimeter-wave Doppler sensor.
even penetrate 10 mm of water.
As for air, α is zero because σ = 0, and both μ and ε are
real numbers. A millimeter wave therefore can propagate in diameter of the millimeter-wave beam with a highly directional
air without loss. The proposed method thus uses the difference antenna and lens is 30 mm, as explained later, because
between α of a target liquid and that of air to measure the minimum beam diameter is limited by the wavelength.
liquid level. Besides liquid water, the proposed method is The required measurement error for medical applications, for
capable of detecting the liquid level if the target liquid has example, is within plus or minus 1 mm. Therefore, accu-
an adequate amount of absorption of a millimeter wave. Some rate measurement (i.e., within sub-millimeter error) against a
water solutions, such as sea water and normal saline solution, spread millimeter-wave beam is necessary.
are conductive and have large α. Blood has dielectric and Fig. 3 shows the architecture of the proposed liquid-level
conductive characteristics [20] and absorbs a millimeter wave. measurement system. A liquid container is placed between our
For liquids that have little or no absorption, such as some kinds developed millimeter-wave Doppler sensor and a piezoelectric
of oils and alcohols, the proposed method is not capable of vibrator. The principle of the measurement is based on the
measuring liquid level when the difference between α of air absorption characteristics of a millimeter wave into a target
and that of the target liquid is inadequate. liquid. The millimeter wave is transmitted from the millimeter-
wave Doppler sensor, shown in Fig. 4, and reflected and
modulated by the vibrator. The Doppler sensor receives the
B. Measurement Architecture modulated wave and calculates the power of the wave, P,
A challenge in measuring liquid level with millimeter waves as explained in Section III D. By moving the container, it
is accuracy. A simple architecture with a millimeter wave is possible to measure P, which is affected by the wave-
transmitter and receiver is shown in Fig. 2. A liquid container propagation path, as a function of the vertical direction (z).
is placed between the transmitter and receiver. By moving Because the millimeter wave is absorbed by liquid and can
the container, millimeter-wave absorption can be measured, penetrate plastic containers and paper labels, the liquid level
and liquid level can be estimated. However, the millimeter- can be determined from P(z).
wave beam inherently spreads due to diffraction, even though Figure 5 shows the beam profile of the developed
the antenna and lens are carefully designed. For example, the millimeter-wave Doppler sensor at the beam waist, which
NAKAGAWA et al.: CONTACTLESS LIQUID-LEVEL MEASUREMENT 929
5
Vibrator
Normalized power (dB)
0 diameter: 5 mm Antenna PA
Divider Divider
-5
Mixer Oscillator
-10
LNA
-15 Beam diameter: 30 mm
(a)
-20
Second lens
-25
-60 -40 -20 0 20 40 60
Distance from beam axis (mm) First lens
60 Plastic package
40 (b) (c)
Beam size (mm)
pHEMT process. The size of the chip is 2.7 × 1.3 mm2 . Millimeter-wave
The chip contains all the necessary millimeter-wave functional Doppler sensor
blocks for the Doppler sensor. A single microstrip patch
antenna with an external dielectric lens is used for cost
effectiveness compared to an array antenna.
The package of the chip is made of low-cost plastic, and
the first lens is mounted on the package. The dome-shaped
first lens collimates the radiation beam and compensates for
Piezoelectric
lack of gain obtained only from the single patch antenna. vibrator
The packaged sensor chip is included in the sensor module,
which has the second plastic lens on the cover of the module. Target liquid
These two lenses narrow the radiation beam and improve container
beam divergence. However, the beam diameter is 30 mm,
even though the lenses are carefully designed. Therefore, the Vertical
proposed architecture with vibrator frequency modulation is linear stage
necessary.
TABLE I
S PECIFICATIONS OF M ILLIMETER -WAVE L IQUID -L EVEL Opaque plastic
M EASUREMENT S YSTEM container
Item Value 50
Frequency 77 GHz
Transmission power 0 dBm
Millimeter-wave Doppler sensor 40
Antenna and lens gain 24 dBi Air
Beam diameter 30 mm
Frequency 2 kHz
Pth
Vibrator 30
Diameter 5 mm
z (mm)
Liquid level
ADC 16 bits
Baseband signal processing Sampling frequency 20 kHz
Signal processing FFT 20
Water
60 10
Vibrator frequency
40 0
-10 0 10 20 30 40 50
Power (dB)
Measured liquid level (mm) 80 1 had good linearity, and the measured non-linearity error was
within ±0.5 mm.
[21] T. Nozokido, J. Bae, and K. Mizuno, “Scanning near-field millimeter- Hideaki Kurata (M’05) received the B.S. and M.S.
wave microscopy using a metal slit as a scanning probe,” IEEE Trans. degrees in electronic engineering from Kyoto Uni-
Microw. Theory Tech., vol. 49, no. 3, pp. 491–499, Mar. 2001. versity, Kyoto, Japan, in 1993 and 1995, respec-
[22] M. Golosovsky, A. Lann, and D. Davidov, “A millimeter-wave near- tively.
field scanning probe with an optical distance control,” Ultramicroscopy, He joined the Central Research Laboratory,
vol. 71, nos. 1–4, pp. 133–141, 1998. Hitachi, Ltd., Tokyo, Japan, in 1995, and was
[23] T. Nagasaku, K. Kogo, H. Shinoda, H. Kondoh, Y. Muto, A. Yamamoto, involved in research and development of high-
and T. Yoshikawa, “77 GHz low-cost single-chip radar sensor for auto- density and multilevel flash memories. From 2006
motive ground speed detection,” in Proc. Int. Symp. Comp. Semicond. to 2007, he was a Visiting Researcher with Stanford
Circuits, Oct. 2008. pp. 1–4. University, Stanford, CA. Since 2007, he has been
engaged in research and development of micro-
electromechanical systems and various sensors for automotive and biomedical
applications.
Mr. Kurata was a member of the ISSCC Technical Program Committee from
2008 to 2010.
Tatsuo Nakagawa received the B.S. degree in geo-
physics from Tohoku University, Sendai, Japan, and
the M.E. degree in advanced energy engineering
from the University of Tokyo, Tokyo, Japan, in 2002
and 2004, respectively. Kenichi Osada (M’95) was born in Nagano, Japan,
He has been with the Central Research Laboratory, in 1969. He received the B.S., M.S., and Ph.D.
Hitachi, Ltd., Tokyo, since 2004, where he has degrees in electrical engineering from Keio Uni-
been engaged in development of sensor network versity, Tokyo, Japan, in 1992, 1994, and 2005,
systems and devices. His current research interests respectively.
include analog and mixed signal circuits, wireless He joined the Central Research Laboratory of
communication and sensing systems, power devices, Hitachi, Ltd., Tokyo, in 1994, and was involved in
and sensors for medical instruments. research and development of high-speed and low-
power circuits for cache memories of SH-4 and
SH-5 microprocessors. From 2000 to 2002, he devel-
oped low-power 16-MB SRAM and invented several
design techniques to prevent cosmic-ray-induced soft errors and reduce gate
tunnel-leakage currents. He is currently leading research groups on digital and
Akihiko Hyodo received the B.E., M.E., and analog circuits and architectures.
Ph.D. degrees in computer science and communica-
tion engineering from Kyushu University, Fukuoka,
Japan, in 1999, 2001, and 2004, respectively.
He has been with the Central Research Laboratory,
Hitachi, Ltd., Tokyo, Japan, since 2004, where he
Shigeru Oho (M’88) received the B.E. degree from
has been engaged in development of controllers and
sensors for automotive applications. the University of Electro-Communications, Tokyo,
Dr. Hyodo is a member of SAE, SICE, and IPSJ. Japan, in 1978, and the M.E. and Ph.D. degrees from
the Tokyo Institute of Technology, Tokyo, in 1980
and 1997, respectively.
He joined the Hitachi Research Laboratory,
Hitachi, Ltd., Tokyo, in 1980. From 1986 to 1987,
he was a Visiting Scientist with the Massachusetts
Institute of Technology, Cambridge. From 1997 to
2006, he was the Manager with the Automotive
Kenji Kogo has been with the Central Research Product Research Laboratory, Hitachi America, Ltd.,
Laboratory, Hitachi Ltd., Tokyo, Japan, since 1997, Detroit, MI. In 2006, he joined the Central Research Laboratory, Hitachi,
where he has been engaged in development of Ltd., Tokyo, as a Chief Researcher. In 2012, he joined the Nippon Institute of
high-speed transmission devices, optical modules for Technology, Saitama, Japan, where he is currently a Professor. He is involved
optical interconnection, power amplifiers, and radar in research on automotive electronics that encompasses in-vehicle networks,
sensors. car navigation, engine control, embedded real-time systems, and model-based
development technologies.
Dr. Oho was a recipient of the R&D 100 Award in 1993 for the development
of fiber optic gyroscopes for automobiles. He is a member of the IEICE, SICE,
and JSAE.