Infrared moisture meter with fast calibration device and calibration and automatic calibration method thereof

Abstract

The present disclosure relates to an infrared moisture meter with a rapid calibration device and a calibration and automatic calibration method thereof, and belongs to the technical field of moisture detection. The infrared moisture meter with the rapid calibration device comprises a main control unit, a motor, a light source, a chopper, a plano-convex lens, a measurement probe, a punching mirror, a measurement window, a reference probe, a rapid calibration device assembly, a mirror, a reference window, a first condenser, a second condenser and a first quick connector. The rapid calibration device assembly comprises a structural shell, a ventilation hole, a metal container, a heating wire, a weight sensor and a second quick connector. The technical solution of the present disclosure improves the accuracy of equipment detection and the applicability of different materials when the equipment is operated for a long time or the material to be detected is changed. The present disclosure solves the complex problem of on-site calibration of existing infrared online moisture meters, improves the calibration efficiency of the equipment and greatly reduces the maintenance cost of the equipment.

Description

Technical Field

[0001] This disclosure belongs to the field of moisture detection technology, and in particular relates to an infrared moisture meter with a rapid calibration device and its calibration and automatic calibration method. Background Technology

[0002] Infrared moisture analyzers use the principle of infrared spectral absorption. When infrared light of a specific wavelength shines on the surface of a water-containing material, materials with different moisture contents will absorb the infrared light to different degrees. Therefore, by detecting the amount of infrared light energy reflected back by the material, the moisture content of the material can be distinguished.

[0003] Infrared moisture meters are significantly affected by changes in the type, texture, and particle size of materials used on-site. Calibration is necessary when these changes occur. Currently, the calibration method involves taking a sample of material during operation and recording the current moisture content. The material is then dried to calculate its actual moisture content, and the infrared moisture meter reading is corrected to reflect the actual measured value after drying. This method typically requires sending the material to a laboratory for moisture testing or purchasing drying and weighing equipment, increasing equipment maintenance costs.

[0004] As an optical instrument, infrared moisture meters are susceptible to degradation over long periods of operation due to factors such as light source attenuation, optical component contamination, mechanical aging, and system drift, leading to decreased measurement accuracy. Current technology utilizes a built-in dual-optical-path structure, designing infrared moisture meters with an auxiliary optical path to compensate for the impact of light intensity variations by measuring the light energy of the auxiliary path. However, errors caused by system drift and mechanical aging are difficult to compensate for.

[0005] Therefore, it is necessary to provide a new infrared moisture meter with a rapid calibration device and its calibration and automatic calibration method to solve the above-mentioned technical problems. Summary of the Invention

[0006] The purpose of this disclosure is to provide an infrared moisture meter with a rapid calibration device and a calibration and automatic calibration method thereof in order to solve the above-mentioned problems.

[0007] This disclosure achieves the above objectives through the following technical solutions:

[0008] An infrared moisture meter with a rapid calibration device includes a main control unit, a motor, a light source, a chopper, a plano-convex lens, a measuring detector, a punched reflector, a reference detector, a reflector, a first condenser lens, and a second condenser lens, all housed within the moisture meter housing.

[0009] The motor, the light source, the measuring detector, and the reference detector are all connected to the main control unit;

[0010] The chopper is mounted on the output shaft of the motor and is used to modulate the infrared light emitted by the light source.

[0011] The moisture meter housing has two through holes on its bottom side, one for measuring and the other for referencing.

[0012] A rapid calibration device assembly is installed on the bottom side of the moisture meter housing. The rapid calibration device assembly is connected to the main control unit and is adapted to the reference window.

[0013] The punched reflector is positioned directly above the measurement window, the measurement detector is positioned directly above the punched reflector, and the first condenser lens is positioned directly above the measurement detector.

[0014] The reflector is positioned directly above the reference window, the reference detector is positioned directly above the reflector, and the second condenser is positioned directly above the reference detector.

[0015] As a further optimization of this disclosure, the rapid calibration device assembly includes a structural housing, a weight sensor is disposed on the bottom side of the interior of the structural housing, a metal container is disposed on the weight sensor, a heating wire is disposed on the metal container, and both the metal container and the heating wire are connected to the main control unit.

[0016] As a further optimization of this disclosure, the outer shell of the structure is provided with ventilation holes.

[0017] As a further optimization of this disclosure, a first quick connector is provided on one side of the moisture meter housing, and a second quick connector is provided on one side of the structural housing. The main control unit is connected to the rapid calibration device assembly through the first quick connector and the second quick connector.

[0018] As a further optimization of this disclosure, both the heating wire and the weight sensor are electrically connected to the second quick connector.

[0019] As a further optimization of this disclosure, the perforated reflector has several 45-degree angled perforations to allow some light to be reflected and some light to be transmitted.

[0020] As a further optimization of this disclosure, the rapid calibration device assembly is threadedly connected to the reference window.

[0021] A calibration method for an infrared moisture analyzer with a rapid calibration device, comprising:

[0022] Remove the rapid calibration device components;

[0023] The main control unit controls the light source to emit near-infrared light, which is modulated by a chopper and transmitted to a plano-convex lens. The plano-convex lens focuses the infrared light and transmits it to a perforated reflector. The perforated reflector reflects a portion of the light through the measurement window to the material surface. The material surface absorbs and reflects this beam of light, and the first condenser lens receives the diffusely reflected light to the measurement detector. A portion of the light passes through the perforated reflector and then through the reflector to the reference window on the material surface. The material surface absorbs and reflects this beam of light, and the second condenser lens receives the diffusely reflected light to the reference detector. Since the measurement detector and the reference detector are detecting the same material, the initial moisture content detected by the two detectors is consistent, and the initial moisture content is set to W0.

[0024] Place a certain amount of material into the metal container inside the rapid calibration device assembly, and install the rapid calibration device assembly at the reference window;

[0025] The main control unit receives the weight sensing signal sent by the weight sensor and analyzes the weight of the material as M, and controls the heating wire to heat. By detecting the weight loss of the material m, the actual moisture content of the material is calculated, and the actual moisture content W1 = m / M.

[0026] The moisture content detected by the reference detector is corrected to the actual moisture content calculated by the rapid calibration device components, and the correction coefficient is calculated as k=W1 / W0;

[0027] The measurement detector is calibrated by incorporating the correction coefficient.

[0028] The water content is measured by a detector as W = Wi * k, where Wi is the real-time water content measured by the detector.

[0029] As a further optimization of this disclosure, if the change in the weight sensing signal is less than a set threshold within a preset time period detected by the weight sensor, the material is considered to be dried.

[0030] An automatic calibration method for an infrared moisture meter with a rapid calibration device includes the following steps:

[0031] Take a certain amount of material and place it in the metal container inside the rapid calibration device assembly. Install the rapid calibration device assembly at the reference window.

[0032] The main control unit controls the heating wire to continue heating until the moisture is dried, at which point the moisture content of the material W1=0.

[0033] The reference detector monitors the drying material in real time, and the real-time detection value is W2.

[0034] Calculate the value of W2-W1. If the difference is greater than the preset deviation threshold, then perform calibration. The correction coefficient b = W1-W2.

[0035] Substituting the correction coefficient into the measuring detector, the detected water content is W=Wi+b, where Wi is the real-time water content detected by the measuring detector.

[0036] The beneficial effects of this disclosure are as follows:

[0037] This device provides a rapid calibration method when the equipment is running for extended periods or when the material being tested changes, improving the accuracy of the equipment's detection and its applicability to different materials. Furthermore, the rapid calibration device solves the complex on-site calibration problems of existing infrared online moisture meters, significantly reducing equipment maintenance costs. Installed at the equipment's reference window, which monitors the dried material in real time, the device allows for real-time online calibration, eliminating measurement errors caused by instrument drift and improving the accuracy of measurement data. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the overall structure in an embodiment of this disclosure;

[0039] Figure 2 This is a schematic diagram of the rapid calibration device component structure in an embodiment of this disclosure;

[0040] Figure 3 This is a schematic diagram of an infrared moisture meter structure with the rapid calibration device component removed from an embodiment of this disclosure.

[0041] In the diagram: 1. Main control unit; 2. Motor; 3. Light source; 4. Chopper; 5. Plano-convex lens; 6. Measurement detector; 7. Perforated reflector; 8. Measurement window; 9. Reference detector; 10. Quick calibration device assembly; 11. Reflector; 12. Reference window; 13. First condenser lens; 14. Second condenser lens; 15. First quick connector; 101. Structural housing; 102. Ventilation vent; 103. Metal container; 104. Heating wire; 105. Weight sensor; 106. Second quick connector. Detailed Implementation

[0042] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0043] like Figure 1 As shown, an infrared moisture meter with a rapid calibration device includes a main control unit 1, a motor 2, a light source 3, a chopper 4, a plano-convex lens 5, a measurement detector 6, a perforated reflector 7, a measurement window 8, a reference detector 9, a rapid calibration device assembly 10, a reflector 11, a reference window 12, a first condenser lens 13, a second condenser lens 14, and a first quick connector 15.

[0044] The main control unit 1 is connected to the motor 2, driving and controlling the motor 2 to achieve stable rotation. The main control unit 1 is also connected to the light source 3 to drive the light source to illuminate. The main control unit 1 is connected to the measuring detector 6 and the reference detector 9 to detect and process the detection signals, converting them into moisture content. The main control unit 1 is connected to the rapid calibration device assembly 10 via the first quick connector 15 and the second quick connector 106.

[0045] Chopper 4 is mechanically connected to motor 2. The rotation of motor 2 will drive chopper 4 to rotate.

[0046] Near-infrared light emitted by light source 3 is modulated by chopper 4 and transmitted to plano-convex lens 5. Plano-convex lens 5 focuses the light emitted by the light source and transmits it to perforated reflector 7. Perforated reflector 7 reflects a portion of the light through measuring window 8 to the material surface. The material surface absorbs and reflects this beam of light, and first condenser lens 13 receives the diffusely reflected light to measuring detector 6. A portion of the light passing through perforated reflector 7 passes through the perforation in perforated reflector 7 to reflector 11. Reflector 11 reflects the light through reference window 12 to the material surface inside rapid calibration device assembly 10. The material surface absorbs and reflects this beam of light, and second condenser lens 14 receives the diffusely reflected light to reference detector 9.

[0047] The perforated reflector 7 has several 45° angled perforations, allowing some light to be reflected and some light to be transmitted.

[0048] like Figure 2 As shown, a rapid calibration device assembly 10 includes a structural housing 101, a ventilation port 102, a metal container 103, a heating wire 104, a weight sensor 105, and a second quick connector 106.

[0049] The outer casing 101 has ventilation holes 102.

[0050] The metal container 103 is placed on the weight sensor 105 through the heating wire 104.

[0051] Heating wire 104 and weight sensor 105 are both electrically connected to the second quick connector 106.

[0052] When the first quick connector 15 is connected to the second quick connector 106, the main control unit 1 is connected to the heating wire 104 and the weight sensor 105. When the main control unit 1 detects signals from the weight sensor 105 and the heating wire 104, it triggers the main control unit control logic. The main control unit 1 monitors the weight sensor signal in real time. Since the weight of the metal container 103 is known, the weight of the material inside can be determined. The main control unit 1 controls the heating wire 104 to heat the material. When the weight sensor signal change is less than 0.01g within 2 minutes, the material is considered to be dried. The main control unit calculates the actual moisture content of the material inside based on the weight reduction.

[0053] The rapid calibration device 10 is threadedly connected to the moisture meter reference window 12.

[0054] A rapid calibration method:

[0055] 1) Remove the rapid calibration device component 10, such as Figure 3 As shown, since the two detectors (measuring detector 6 and reference detector 9) are detecting the same material, the initial values ​​of the moisture content detected by the two detectors are consistent, and the initial value of the moisture content is W0.

[0056] 2) Place a certain amount of material into the metal container 103 inside the rapid calibration device assembly 10, install the rapid calibration device assembly 10 on the reference window 12, and connect the rapid calibration device control line.

[0057] 3) The main control unit 1 detects the weight sensor signal, analyzes the weight M of the material, and controls the heating wire 104 to heat. By detecting the weight m of water loss of the material, the actual moisture content of the material is calculated. The actual moisture content W1 = m / M.

[0058] 4) Correct the moisture content detected by the reference detector 9 to the actual moisture content calculated by the rapid calibration device component 10, and calculate the correction coefficient, which is k=W1 / W0;

[0059] 5) Input the correction coefficient into the measuring detector 6 to complete the equipment calibration. The main detected water content W = Wi * k (Wi is the real-time value of the water content detected by the measuring detector 6).

[0060] A rapid calibration device is provided, in which a certain amount of material is placed in the rapid calibration device component 10, and the material is periodically dried and tested. By real-time detection of the material moisture content in the reference channel (composed of reference detector 9, reflector 11, reference window 12, and second condenser lens 14), the main measurement channel (composed of measurement detector 6, perforated reflector 7, measurement window 8, and first condenser lens 13) is corrected in real time, which can eliminate measurement errors caused by system drift and improve measurement accuracy.

[0061] An automatic calibration method:

[0062] 1) Take a certain amount of material and place it in the metal container 103 inside the rapid calibration device assembly 10. Install the device in the reference window 12 and connect the rapid calibration device control line.

[0063] 2) The main control unit 1 detects and controls the heating wire 104 to continue heating. After the moisture is dried, the moisture content of the material W1=0.

[0064] 3) The reference channel monitors the drying material in real time, and the real-time monitoring value is W2;

[0065] 4) Calculate W2-W1. If the difference is large (the deviation can be set), then perform calibration. The correction coefficient b = W1-W2.

[0066] Substituting the correction factor into the measuring detector 6, W = Wi + b, where Wi is the real-time moisture value detected by the measuring detector 6.

[0067] The embodiments described above are merely examples of several implementations of this disclosure, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent disclosure. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this disclosure, and these modifications and improvements all fall within the protection scope of this disclosure.

Claims

1. An infrared moisture meter with a rapid calibration device, characterized in that, The device includes a main control unit (1), a motor (2), a light source (3), a chopper (4), a plano-convex lens (5), a measuring detector (6), a perforated reflector (7), a reference detector (9), a reflector (11), a first condenser (13), and a second condenser (14), all housed within the moisture meter housing. The motor (2), the light source (3), the measuring detector (6), and the reference detector (9) are all connected to the main control unit (1); The chopper (4) is mounted on the output shaft of the motor (2) and is used to modulate the infrared light emitted by the light source (3); The moisture meter housing has two through holes on the bottom side, namely a measurement window (8) and a reference window (12). A rapid calibration device assembly (10) is installed on the bottom side of the moisture meter housing. The rapid calibration device assembly (10) is connected to the main control unit (1) and is adapted to the reference window (12). The punched reflector (7) is positioned directly above the measuring window (8), the measuring detector (6) is positioned directly above the punched reflector (7), and the first condenser lens (13) is positioned directly above the measuring detector (6). The reflector (11) is positioned directly above the reference window (12), the reference detector (9) is positioned directly above the reflector (11), and the second condenser (14) is positioned directly above the reference detector (9).

2. An infrared moisture meter with a rapid calibration device according to claim 1, characterized in that, The rapid calibration device assembly (10) includes a structural housing (101), a weight sensor (105) is provided on the bottom inside the structural housing (101), a metal container (103) is provided on the weight sensor (105), a heating wire (104) is provided on the metal container (103), and both the metal container (103) and the heating wire (104) are connected to the main control unit (1).

3. An infrared moisture meter with a rapid calibration device according to claim 2, characterized in that, The outer shell (101) of the structure is provided with ventilation holes (102).

4. An infrared moisture meter with a rapid calibration device according to claim 2, characterized in that, A first quick connector (15) is provided on one side of the moisture meter housing, and a second quick connector (106) is provided on one side of the structural housing (101). The main control unit (1) is connected to the rapid calibration device assembly (10) through the first quick connector (15) and the second quick connector (106).

5. An infrared moisture meter with a rapid calibration device according to claim 4, characterized in that, The heating wire (104) and the weight sensor (105) are both electrically connected to the second quick connector (106).

6. An infrared moisture meter with a rapid calibration device according to claim 1, characterized in that, The perforated reflector (7) has several 45-degree angled perforations to allow some light to be reflected and some light to be transmitted.

7. An infrared moisture meter with a rapid calibration device according to claim 1, characterized in that, The rapid calibration device assembly (10) is threadedly connected to the reference window (12).

8. A calibration method for an infrared moisture analyzer with a rapid calibration device as described in any one of claims 2-5, characterized in that, include: Remove the rapid calibration device component (10); The main control unit (1) controls the light source (3) to emit near-infrared light, which is modulated by the chopper (4) and transmitted to the plano-convex lens (5). The plano-convex lens (5) focuses the infrared light and transmits it to the perforated reflector (7). The perforated reflector (7) reflects a portion of the light through the measurement window (8) to the material surface. The material surface absorbs and reflects the light beam. The first condenser (13) receives the diffusely reflected light to the measurement detector (6). A portion of the light beam passes through the perforated reflector (7) and through the hole to the reflector (11). The reflector (11) reflects the light beam through the reference window (12) to the material surface. The material surface absorbs and reflects the light beam. The second condenser (14) receives the diffusely reflected light to the reference detector (9). Since the measurement detector (6) and the reference detector (9) are detecting the same material, the initial values ​​of the moisture content detected by the two detectors are consistent. The initial value of the detected moisture content is set to W0. Take a certain amount of material and place it in the metal container (103) inside the rapid calibration device assembly (10). Install the rapid calibration device assembly (10) on the reference window (12). The main control unit (1) receives the weight sensing signal sent by the weight sensor (105) and analyzes the weight of the material as M, and controls the heating wire (104) to heat. By detecting the weight loss of the material m, the actual moisture content of the material is calculated, and the actual moisture content W1 = m / M. The moisture content detected by the reference detector (9) is corrected to the actual moisture content calculated by the rapid calibration device assembly (10), and the correction coefficient is calculated as k=W1 / W0; Substitute the measurement detector (6) into the correction coefficient to complete the equipment calibration; The water content was detected by the detector (6) as W=Wi k, where Wi is the real-time value of moisture detected by the measuring detector (6).

9. The calibration method according to claim 8, characterized in that, When the weight sensor (105) detects that the change in the weight sensor signal within a preset time period is less than the set threshold, it is considered that the material has been dried.

10. An automatic calibration method for an infrared moisture analyzer with a rapid calibration device as described in any one of claims 2-5, characterized in that, Includes the following steps: Take a certain amount of material and place it in the metal container (103) inside the rapid calibration device assembly (10). Install the rapid calibration device assembly (10) on the reference window (12). The main control unit (1) controls the heating wire (104) to continue heating. After the moisture is dried, the moisture content of the material is W1=0. The reference detector (9) detects the dried material in real time, and the real-time detection value is W2; Calculate the value of W2-W1. If the difference is greater than the preset deviation threshold, then perform calibration. The correction coefficient b = W1-W2. Substituting the correction coefficient into the measuring detector (6), the detected water content is W=Wi+b, where Wi is the real-time value of the water content detected by the measuring detector (6).

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