Radar system detects filling levels.

The radar experts at InnoSenT GmbH have developed a new system for focused distance measurement. The iSYS-6030 is the new edition of the successful iSYS-6003 filling-level radar. The product update is more economical, faster, and more accurate than its predecessor. The sensor’s features are adapted to the application of filling-level measurement and collision avoidance. The technical enhancements also extend the scope of applications.

Using contactless radar detection, the product accurately detects the filling level of a manufacturing or storage container. The iSYS-6030 radar system sporadically determines the distance between the sensor and an object’s surface. Thanks to its narrow antenna orientation, the product has a focused radar beam for high-precision measurements.

The iSYS-6030 detects a wide variety of materials regardless of their properties and reflection characteristics: Whether cohesive or coarse bulk materials, fine powder, granulate, slow-flowing liquids, or viscous pastes, the system detects any of these materials precisely thanks to its 60 GHz radar technology.

The new product handles the measurement of filling levels even in challenging indoor and outdoor measuring environments. Extreme temperatures, dust, fog, steam, formation of foam, vibrations, or pressure do not impede radar detection. Due to its focused field of view of 6° in azimuth and elevation, the system is also suitable for use in narrow vessels, asymmetrical special structures, or containers with internal mixing systems installed. The iSYS-6030 also provides reliable measurement results in this area by means of sporadic radar detection.

The robust technology is not susceptible to interference due to aggressive filling materials, harsh work environments, or dirt. No regular maintenance is necessary. This makes the product well-suited for use in many different sectors, such as the water, energy, construction materials, food, chemical, pharmaceutical, and environmental technology industries.

While the predecessor product was primarily focused on determining filling levels, the iSYS-6030 boasts a further area of application: thanks to its continuous and reliable distance monitoring, the system is ideally suited for collision protection.

Thanks to technical optimisation, the new product enables faster measuring cycles. The system is booted up and ready to collect data within 90 ms. The update rate in single-target mode is only 20 ms. This enables intervals to be monitored in real time and timely warnings in the event of an impending collision.

In another application, the radar helps to initiate safety measures such as speed reduction when a predefined zone is reached. The user defines the zone individually using the distance information. The iSYS-6030 radar system provides information on when the safety distance is neared or the zone is reached.

Integrating such a system proves beneficial not only with semi-autonomous and autonomous vehicles, but also for controlling complex systems. The radar system continuously collects accurate measurement data. These are useful in maintaining minimum distances and precise positioning. At port facilities, this enables a distance between cranes, transport units, buildings, or containers to thus be determined on site with millimetre precision.

The iSYS-6030 radar system operates in the frequency band from 57 to 64 GHz. The sensor is compact and equipped with a signal-processing unit and a dome-shaped radome. The radar component can thus be easily integrated into end products or customer housings. The measurement data (signal strength and distance) are provided as a target list via a UART interface. The maximum range is 40 metres.

Customers choose between two detection variants, depending on the application: single-target and multi-target mode. This way, the system measures the distance to the object surface either at a single point or at different points within the detection area. The radar distinguishes between two targets with the same radar cross-section with a resolution of 12 cm.

The low deviation rate of ±0.1% ensures outstanding precision even with increasing distance between the object and the sensor. The system can be operated in a temperature range of -40 to +85° C.

Since the new system has the same structural design, it can directly replace the old iSYS-6003 product version and offers useful enhancements to existing customers.

‘We have made significant progress in radar development in recent years. In addition, we have learned quite a bit about our customers’ needs through the practical use of our filling-level radar. We thus decided to optimise the system’, explains Product Manager Dr Eva Buchkremer regarding the product update, and she adds:

‘Compared to its predecessor, the iSYS-6030 is more energy-efficient and accurate, longer-range and faster. We thus provide our customers with greater flexibility in using the product. We also offer more customisation options. Its technical features make the new system the ideal radar solution in industry for avoiding collisions and measuring filling levels.’

Using the user manual and the API software protocol, the customer adapts the radar detection to their intended purpose. For example, they can limit the range or use the signal strength setting as a filter. In addition, customers have the option of configuring the effective isotropic radiated power (EIRP) in 1 dBm increments, for example in order to comply with technical limits required for approval purposes.

The system also has four digitally, freely assignable and programmable outputs. These enable simple control tasks and can be used as targeted signal triggers. For easy integration and configuration of the sensor, InnoSenT also provides an evaluation kit with a GUI.

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