High-precision liquid level detection method

Abstract

The invention belongs to the technical field of high-precision liquid level detection, and particularly relates to a high-precision liquid level detection method which comprises an installation preparation module, an installation position determination module, a comprehensive consideration module and a special installation method module. And the liquid level detection precision can be obviously improved. The photoelectric sensor is sensitive to light change and suitable for directly detecting the liquid surface; the ultrasonic sensor determines the distance by measuring the propagation time of sound waves, and is relatively insensitive to the change of liquid properties. The combination of the two can complement deficiencies and reduce errors.

Description

Technical Field

[0001] This invention belongs to the field of high-precision liquid level detection technology, and specifically relates to a high-precision liquid level detection method. Background Technology

[0002] Liquid level detection technology plays a vital role in numerous fields, including industry, agriculture, environmental protection, and daily life. With technological advancements and ever-increasing application demands, liquid level detection requires more than just basic level measurement; it demands higher accuracy, stability, and adaptability. Traditional liquid level detection methods, such as float switches and servo level gauges, while simple in structure and low in cost, fall short when facing complex environments and high-precision requirements.

[0003] First, in terms of measurement accuracy and stability, mechanical sensors such as float switches are prone to errors or even jamming due to liquid fluctuations, corrosion, or changes in viscosity. Furthermore, their installation and maintenance costs are relatively high, making it difficult to meet the demands for high precision and long lifespan.

[0004] Secondly, with the rapid development of computer and chip technologies, new types of sensors such as photoelectric level sensors, ultrasonic level sensors, and radar level gauges are gradually emerging. These sensors have advantages such as non-contact measurement, high precision, good stability, and ease of installation and maintenance, effectively solving many drawbacks of traditional level detection methods. In particular, photoelectric level sensors achieve high-precision level detection by detecting the refraction or reflection of light as it propagates through a liquid, and are not easily affected by external environmental interference.

[0005] However, a single liquid level detection method often cannot meet the needs of all application scenarios. For example, in large storage tanks or complex containers, due to the diversity of liquid properties, container shape, and internal structure, a single sensor cannot fully cover the liquid level range or may be affected by obstacles. Summary of the Invention

[0006] The purpose of this invention is to provide a high-precision liquid level detection method to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a high-precision liquid level detection method, comprising an installation preparation module, an installation location determination module, a comprehensive consideration module, and a special installation method module, wherein the installation preparation module includes the following steps; S1: Requirements analysis, clarifying the specific application scenarios of liquid level detection, including liquid type, container shape, measurement range, accuracy requirements, and environmental conditions; S2: Select the appropriate photoelectric liquid level sensor and ultrasonic liquid level sensor model according to the requirements to ensure that they can meet the measurement requirements; S3: Tools and materials preparation. Prepare the tools needed for installation, such as screwdrivers, wrenches, and electric drills. S4: Prepare necessary installation materials, such as mounting brackets, screws, washers, cables, etc. The installation location determination module includes the following steps; S1: Installation location of the photoelectric liquid level sensor. Choose a location that can directly touch the liquid to ensure that the sensor can fully cover the high and low liquid level range. Avoid installing it in places with obstructions or light interference to ensure the normal operation of the photoelectric sensor. S2: Choose a location close to the liquid surface and without any obstructions to ensure that the ultrasonic waves can be successfully transmitted and the reflected signals can be received. The installation location should avoid areas that are prone to interference signals, such as vibration sources and electromagnetic interference sources. S3: Fixture installation. Select a suitable fixture according to the size and weight of the sensor and install it in the predetermined position. Use screws to firmly fix the fixture to the container wall to ensure that the fixture is stable and reliable. S4: Sensor installation. Install the photoelectric liquid level sensor on the bracket, ensuring that the part of the sensor in contact with the liquid is unobstructed and can move freely. Then install the ultrasonic liquid level sensor, fix it on the bracket and adjust it to a suitable angle and height to ensure that the ultrasonic waves can be successfully transmitted and received. S5: Cable connection: Connect the cables of the photoelectric liquid level sensor and the ultrasonic liquid level sensor to the monitoring equipment or data acquisition system respectively, and ensure that the cable connection is firm and reliable, without loosening or short circuit. S6: Parameter setting and debugging. According to the requirements of the sensor and monitoring equipment, set the sensor parameters, such as measurement range, accuracy requirements, output signal type, etc., and carry out debugging work to ensure that the two sensors can work normally and output accurate liquid level data. The comprehensive consideration module needs to select a location that meets the installation requirements of both the photoelectric liquid level sensor and the ultrasonic liquid level sensor, based on the shape and internal structure of the container, and ensure that the installation locations of the two sensors do not interfere with each other and can work together to improve the accuracy of liquid level detection. The special installation method module includes special debugging and calibration methods.

[0008] Preferably, the module for determining the installation location includes an installation location selection module, and the location selection module includes the following steps; S1; Avoid obstacles: Ensure that there are no obstacles within the beam range emitted by the sensor, such as pipes, supports, stirrers, etc., to avoid interfering with the emission and reception of the beam. The optical path of the photoelectric liquid level sensor should be clear and free from other objects blocking the light. S2: Parallel installation: For ultrasonic level sensors, the emitting surface should be parallel to the liquid surface being measured to ensure that the sound waves are emitted perpendicularly to the liquid surface and improve measurement accuracy; S3: Based on the sensor's range and blind zone: reasonably determine the distance between the sensor and the liquid surface being measured, avoid entering the blind zone, and ensure that the photoelectric liquid level sensor's photosensitive part can be completely immersed in the liquid, while avoiding contact with the bottom or side of the container. S4: Avoid areas with large fluctuations: Avoid installing the sensor in areas with large liquid fluctuations, such as inlet / outlet and stirring areas, to reduce measurement errors.

[0009] Preferably, the special installation method module includes tilt installation, multi-sensor combination installation, installation of extension tubes, and addition of reflectors.

[0010] Preferably, for certain special shapes or measurement requirements, the tilted installation can ensure that the sensor can cover the liquid surface more comprehensively and reduce measurement errors caused by the shape of the container. However, it should be noted that when tilted, the measurement range of the sensor should still be within the effective area of ​​the liquid surface being measured.

[0011] Preferably, the multi-sensor combination installation can be used in some situations requiring high-precision measurement. Multiple ultrasonic level sensors can be installed at different locations on the container, and the measurement results of multiple sensors can be fused through data processing algorithms to improve the accuracy and reliability of the measurement.

[0012] Preferably, when there are obstacles in the container or the liquid level fluctuates greatly, the extension tube can be installed in front of the sensor. The extension tube can isolate the influence of obstacles and fluctuations, enabling the sensor to measure the liquid level more stably.

[0013] Preferably, for ultrasonic level sensors, if the reflection effect between the liquid surface and the bottom or side wall of the container is poor, a reflector can be installed below the liquid surface. The reflector can reflect the ultrasonic waves back to the sensor, improving the strength and stability of the echo signal, thereby improving the accuracy of the measurement.

[0014] Preferably, the special debugging and calibration method includes a temperature compensation module, a spurious echo suppression module, and an adaptive calibration module. The temperature compensation module uses temperature compensation technology during installation, which compensates for the influence of temperature on the measurement by measuring the temperature of the liquid and adjusting the sensor's measurement parameters. The spurious echo suppression module uses spurious echo suppression technology to accurately identify the echo signal from the liquid surface. This technology analyzes the characteristics of the echo signal through an algorithm and suppresses non-liquid surface echo signals, thereby improving the accuracy of the measurement. The adaptive calibration module maintains the accuracy of the measurement by monitoring changes in the liquid surface in real time and automatically adjusting the sensor's measurement parameters.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This invention significantly improves the accuracy of liquid level detection by combining the measurement advantages of photoelectric and ultrasonic liquid level sensors. Photoelectric sensors are sensitive to changes in light, making them suitable for directly detecting the liquid surface; while ultrasonic sensors determine distance by measuring the propagation time of sound waves and are relatively insensitive to changes in liquid properties. Combining the two sensors complements each other's weaknesses and reduces errors.

[0016] This invention can flexibly meet the needs of different application scenarios, including different liquid types, container shapes, measurement ranges, accuracy requirements, and environmental conditions. By conducting detailed requirements analysis, a suitable sensor model is selected, and various special installation methods are employed, such as tilted installation, multi-sensor combination installation, installation of extension tubes, and addition of reflectors, to adapt to complex measurement environments.

[0017] This invention ensures the sensor's stability and reliability during measurement through a scientifically sound installation location and fixing method. It avoids obstacles and interference sources, reducing measurement errors; and the rational selection of the installation location and angle ensures the sensor can successfully transmit and receive signals. Furthermore, the use of high-quality mounting brackets and cable connections further enhances the system's stability and reliability. Attached Figure Description

[0018] Figure 1 This is a flowchart of the present invention; Figure 2 Flowchart of the installation preparation module of this invention; Figure 3 Flowchart of the installation location selection module of the present invention; Figure 4 This is a flowchart of the special installation method module of the present invention; Figure 5 This is a flowchart of the special debugging and calibration method module of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please see the appendix Figures 1-5 The present invention provides several embodiments: A high-precision liquid level detection method includes an installation preparation module, an installation location determination module, a comprehensive consideration module, and a special installation method module. The installation preparation module includes the following steps. S1: Requirements analysis, clarifying the specific application scenarios of liquid level detection, including liquid type, container shape, measurement range, accuracy requirements, and environmental conditions; S2: Select the appropriate photoelectric liquid level sensor and ultrasonic liquid level sensor model according to the requirements to ensure that they can meet the measurement requirements; S3: Tools and materials preparation. Prepare the tools needed for installation, such as screwdrivers, wrenches, and electric drills. S4: Prepare necessary installation materials, such as mounting brackets, screws, washers, cables, etc. The steps involved in installing the module to determine the installation location are as follows; S1: Installation location of the photoelectric liquid level sensor. Choose a location that can directly touch the liquid to ensure that the sensor can fully cover the high and low liquid level range. Avoid installing it in places with obstructions or light interference to ensure the normal operation of the photoelectric sensor. S2: Choose a location close to the liquid surface and without any obstructions to ensure that the ultrasonic waves can be successfully transmitted and the reflected signals can be received. The installation location should avoid areas that are prone to interference signals, such as vibration sources and electromagnetic interference sources. S3: Fixture installation. Select a suitable fixture according to the size and weight of the sensor and install it in the predetermined position. Use screws to firmly fix the fixture to the container wall to ensure that the fixture is stable and reliable. S4: Sensor installation. Install the photoelectric liquid level sensor on the bracket, ensuring that the part of the sensor in contact with the liquid is unobstructed and can move freely. Then install the ultrasonic liquid level sensor, fix it on the bracket and adjust it to a suitable angle and height to ensure that the ultrasonic waves can be successfully transmitted and received. S5: Cable connection: Connect the cables of the photoelectric liquid level sensor and the ultrasonic liquid level sensor to the monitoring equipment or data acquisition system respectively, and ensure that the cable connection is firm and reliable, without loosening or short circuit. S6: Parameter setting and debugging. According to the requirements of the sensor and monitoring equipment, set the sensor parameters, such as measurement range, accuracy requirements, output signal type, etc., and carry out debugging work to ensure that the two sensors can work normally and output accurate liquid level data. Taking into account the shape and internal structure of the container, the module needs to select a location that can meet the installation requirements of both photoelectric liquid level sensors and ultrasonic liquid level sensors, and ensure that the installation locations of the two sensors do not interfere with each other and can work together to improve the accuracy of liquid level detection. The special installation method module includes special debugging and calibration methods.

[0021] Furthermore, the installation location determination module includes an installation location selection module, which includes the following steps; S1; Avoid obstacles: Ensure that there are no obstacles within the beam range emitted by the sensor, such as pipes, supports, stirrers, etc., to avoid interfering with the emission and reception of the beam. The optical path of the photoelectric liquid level sensor should be clear and free from other objects blocking the light. S2: Parallel installation: For ultrasonic level sensors, the emitting surface should be parallel to the liquid surface being measured to ensure that the sound waves are emitted perpendicularly to the liquid surface and improve measurement accuracy; S3: Based on the sensor's range and blind zone: reasonably determine the distance between the sensor and the liquid surface being measured, avoid entering the blind zone, and ensure that the photoelectric liquid level sensor's photosensitive part can be completely immersed in the liquid, while avoiding contact with the bottom or side of the container. S4: Avoid areas with large fluctuations: Avoid installing the sensor in areas with large liquid fluctuations, such as inlet / outlet and stirring areas, to reduce measurement errors.

[0022] Furthermore, the special installation method module includes tilt installation, multi-sensor combination installation, installation of extension tubes, and addition of reflectors.

[0023] Furthermore, for certain specially shaped locations or measurement requirements, the sensor can be installed at an angle. This method can ensure that the sensor can more fully cover the liquid surface and reduce measurement errors caused by the shape of the container. However, it should be noted that when installing at an angle, it should be ensured that the sensor's measurement range is still within the effective area of ​​the liquid surface being measured.

[0024] Furthermore, multi-sensor combination installation can be used in some applications requiring high-precision measurement. Multiple ultrasonic level sensors can be installed at different locations on the container, and the measurement results from multiple sensors can be fused through data processing algorithms to improve the accuracy and reliability of the measurement.

[0025] Furthermore, an extension tube can be installed in front of the sensor when there are obstacles or large fluctuations in the liquid level within the container. The extension tube can isolate the effects of obstacles and fluctuations, enabling the sensor to measure the liquid level more stably.

[0026] Furthermore, adding a reflector can improve the accuracy of ultrasonic level sensors. If the reflection effect between the liquid surface and the bottom or side wall of the container is poor, a reflector can be added below the liquid surface. The reflector can reflect the ultrasonic waves back to the sensor, improving the strength and stability of the echo signal, thereby improving the accuracy of the measurement.

[0027] Furthermore, the special debugging and calibration methods include a temperature compensation module, a spurious echo suppression module, and an adaptive calibration module. The temperature compensation module uses temperature compensation technology during installation, which compensates for the influence of temperature on the measurement by measuring the temperature of the liquid and adjusting the sensor's measurement parameters. The spurious echo suppression module uses spurious echo suppression technology to accurately identify the echo signal from the liquid surface. This technology analyzes the characteristics of the echo signal through algorithms and suppresses non-liquid surface echo signals, thereby improving the accuracy of the measurement. The adaptive calibration module maintains the accuracy of the measurement by monitoring changes in the liquid surface in real time and automatically adjusting the sensor's measurement parameters.

[0028] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-precision liquid level detection method, characterized in that: It comprises installation preparation module, installation position determination module, comprehensive consideration module and special installation method module, the installation preparation module comprises the following steps: S1: requirement analysis, clear liquid level detection specific application scene, including liquid type, container shape, measurement range, accuracy requirement, environmental condition; S2: according to the demand, select the appropriate photoelectric liquid level sensor and ultrasonic liquid level sensor model, ensure that they can meet the measurement requirements; S3: tool and material preparation, prepare the tools required for installation, such as screwdriver, wrench, electric drill; S4: prepare the necessary installation materials, such as fixed support, screw, gasket, cable, etc.; The installation position determination module comprises the following steps: S1: photoelectric liquid level sensor installation position, select a position that can directly access the liquid, ensure that the sensor can fully cover the high and low liquid level range of the liquid, avoid installing in places with shelter or light interference, to ensure the normal work of photoelectric sensor; S2: select a position close to the liquid surface and without obstacles, ensure that the ultrasonic wave can be smoothly transmitted and the reflected signal can be received, the installation position should avoid the area prone to interference signal, such as vibration source, electromagnetic interference source, etc.; S3: fixed support installation, according to the size and weight of the sensor, select the appropriate fixed support and install it in the predetermined position, use screw to firmly fix the support on the container wall, ensure that the support is stable and reliable; S4: sensor installation, install the photoelectric liquid level sensor on the support, ensure that the sensor contact part with the liquid is not blocked and can move freely, then install the ultrasonic liquid level sensor, fix it on the support and adjust to the appropriate angle and height, to ensure that the ultrasonic wave can be smoothly transmitted and received; S5: cable connection: connect the cable of photoelectric liquid level sensor and ultrasonic liquid level sensor to the monitoring equipment or data acquisition system respectively, ensure that the cable connection is stable and reliable, without looseness or short circuit phenomenon; S6: parameter setting and debugging, according to the requirements of sensor and monitoring equipment, set the parameters of sensor, such as measurement range, accuracy requirement, output signal type, etc., carry out debugging work, ensure that the two sensors can work normally and output accurate liquid level data; The comprehensive consideration module needs to select a position that can meet the installation requirements of both photoelectric liquid level sensor and ultrasonic liquid level sensor according to the shape and internal structure of the container, and ensure that the installation positions of the two sensors do not interfere with each other, and can work together to improve the accuracy of liquid level detection; The special installation method module includes special debugging and calibration method.

2. The high-precision liquid level detection method of claim 1, wherein: The installation position determination module comprises installation position selection module, the position selection module comprises the following steps: S1: avoid Obstacles: ensure that there is no obstacle in the beam range of the sensor, such as pipeline, support, agitator, etc., so as to avoid interference with the emission and reception of beam, the light path of photoelectric liquid level sensor should be clear, avoid other objects to block the light; S2: parallel installation: for ultrasonic liquid level sensor, its emission surface should be parallel to the measured liquid surface, to ensure that the sound wave is vertically emitted to the liquid surface, improve the measurement accuracy; S3: According to the range and blind area of the sensor: reasonably determine the distance between the sensor and the measured liquid level, avoid entering the blind area range, and ensure that the photosensitive part of the photoelectric liquid level sensor can be completely immersed in the liquid, while avoiding contact with the bottom or side of the container; S4: Avoid the fluctuation area: avoid installing the sensor in the area where the liquid fluctuates greatly, such as the inlet and outlet, stirring area, etc., to reduce the measurement error.

3. The high-precision liquid level detection method of claim 1, wherein: The special installation method module includes inclined installation, multi-sensor combination installation, installation extension pipe and installation of reflective plate.

4. The high-precision liquid level detection method according to claim 3, characterized in that: The inclined installation can be used for some special shape positions or measurement requirements. This method can ensure that the sensor can cover the liquid surface more comprehensively and reduce the measurement error caused by the shape of the container. However, it should be noted that when installing obliquely, the measurement range of the sensor should still be within the effective area of the measured liquid level.

5. The high-precision liquid level detection method according to claim 3, characterized in that: The multi-sensor combination installation can be used in some occasions that require high-precision measurement. Multiple ultrasonic liquid level sensors can be installed at different positions of the container to improve the accuracy and reliability of measurement through data processing algorithm.

6. The high-precision liquid level detection method according to claim 3, characterized in that: The installation extension pipe can be installed in front of the sensor when there are obstacles or large fluctuations in the liquid surface. The extension pipe can isolate the influence of obstacles and fluctuations, so that the sensor can measure the liquid level more stably.

7. The high-precision liquid level detection method according to claim 6, characterized in that: For ultrasonic liquid level sensors, if the reflection effect of the liquid surface and the container bottom or side wall is poor, a reflective plate can be installed below the liquid surface. The reflective plate can reflect the ultrasonic waves back to the sensor, improving the strength and stability of the echo signal, thereby improving the accuracy of measurement.

8. The high-precision liquid level detection method of claim 1, wherein: The special debugging and calibration method includes temperature compensation module, false echo suppression module and adaptive calibration module. The temperature compensation module uses temperature compensation technology during installation to measure the temperature of the liquid and adjust the measurement parameters of the sensor to compensate for the influence of temperature on measurement. The false echo suppression module can accurately identify the echo signal of the liquid surface by using false echo suppression technology. This technology analyzes the characteristics of the echo signal by algorithm and suppresses non-liquid surface echo signals, thereby improving the accuracy of measurement. The adaptive calibration module monitors the changes of the liquid surface in real time and automatically adjusts the measurement parameters of the sensor to maintain the accuracy of measurement.

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