An ultrasonic liquid level sensor test platform and test correction method

Abstract

The application relates to the technical field of drilling equipment, and discloses an ultrasonic liquid level sensor test platform and a test correction method. The ultrasonic liquid level sensor test platform comprises a test frame and a control device. The test frame is sequentially provided with a water tank, an atomization generator and an ultrasonic liquid level sensor to be tested from bottom to top. The water tank is connected with a flow pump so as to adjust the liquid flow rate v in the water tank. The atomization generator is arranged in the water tank so as to adjust the water mist thickness d of the liquid level. The ultrasonic liquid level sensor is connected with the test frame through a lifting adjusting mechanism. The lifting adjusting mechanism is used for adjusting the liquid level distance h from the ultrasonic liquid level sensor to the liquid level. The flow pump, the atomization generator and the lifting adjusting mechanism are all signal-connected with the control device. The ultrasonic liquid level sensor can obtain correction values under different liquid level distances h and liquid level conditions, so as to compensate for the influence of the working environment on the measurement accuracy of the liquid level height.

Description

Technical Field

[0001] This invention relates to the field of drilling equipment technology, and more specifically, to an ultrasonic liquid level sensor testing platform. Furthermore, this invention also provides a testing and calibration method using the aforementioned ultrasonic liquid level sensor testing platform. Background Technology

[0002] During drilling operations, changes in the volume of drilling fluid (commonly known as "mud") can reflect whether there is an overflow or leakage in the formation. Once the wellbore pressure is unbalanced, it will seriously affect the safety of downhole and surface operations. Therefore, it is necessary to monitor the changes in the total volume of drilling fluid in real time during oil drilling operations. Usually, the changes in the total volume of drilling fluid are obtained by detecting changes in the height of the mud tank liquid level.

[0003] Mud tank liquid level alarm or monitoring devices mostly use ultrasonic liquid level sensors, which are highly accurate, fast-responding, and compact in structure. However, due to the special nature of oil exploration and development, the temperature of drilling fluid returning to the mud tank from the formation exceeds 70°C. Under the dual action of circulating air and agitator, water vapor, feed dust, and liquid level fluctuations can all cause significant errors in the liquid level measurement accuracy of ultrasonic liquid level sensors.

[0004] In conclusion, how to reduce the impact of the working environment on the measurement accuracy of ultrasonic liquid level sensors is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide an ultrasonic liquid level sensor testing platform that can obtain the correction values ​​of the ultrasonic liquid level sensor under different liquid level distances h and liquid level conditions, so as to compensate for the influence of the working environment on the accuracy of liquid level measurement.

[0006] In addition, the present invention also provides a test calibration method using the above-mentioned ultrasonic liquid level sensor test platform.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] An ultrasonic liquid level sensor testing platform includes a test frame and a control device. The test frame, from bottom to top, comprises a water tank, an atomizer, and the ultrasonic liquid level sensor to be tested. The water tank is connected to a flow pump to adjust the liquid flow rate v within the tank. The atomizer is located inside the water tank to adjust the water mist thickness d on the liquid surface. The ultrasonic liquid level sensor is connected to the test frame via a lifting adjustment mechanism, which adjusts the distance h between the ultrasonic liquid level sensor and the liquid surface. The flow pump, the atomizer, and the lifting adjustment mechanism are all signal-connected to the control device.

[0009] Preferably, the lifting adjustment mechanism includes a gear belt arranged along the height direction. The gear belt is connected to the ultrasonic liquid level sensor. The upper and lower ends of the gear belt are respectively sleeved on the outside of a gear. The gear at one end of the gear belt is connected to a servo motor. When the servo motor rotates, the gear drives the gear belt to move up and down along the height direction, and drives the ultrasonic liquid level sensor to move up and down along the height direction.

[0010] Preferably, the gear is rotatably mounted on the upper and lower ends of the slide housing, the gear belt is connected to the slide base, the slide base is connected to the horizontally arranged instrument mounting plate, and the ultrasonic liquid level sensor is mounted on the instrument mounting plate.

[0011] Preferably, the servo motor is connected to the gear via a reducer, and the reducer has a locking function.

[0012] Preferably, the control device includes a control box, which contains a wireless receiver. The control box can control the rotation of the servo motor via wired or wireless means.

[0013] Preferably, the lifting and adjusting mechanism is located on one side of the test frame, and the water tank is provided with a water tank splash guard that is higher than the liquid level. The water tank splash guard is used to prevent liquid from splashing into the lifting and adjusting mechanism.

[0014] Preferably, the test frame has a protruding lateral mounting plate on its side, and a diagonal bracing beam is provided between the lateral mounting plate and the test frame. The flow pump and the control device are both located on the lateral mounting plate.

[0015] Preferably, the bottom of the test frame is provided with height-adjustable pulleys, which have a locking function.

[0016] A test calibration method, using the ultrasonic liquid level sensor test platform described in any one of the above claims, includes:

[0017] By controlling the liquid surface distance h, water mist thickness d, and liquid flow velocity v through orthogonal experiments, the liquid surface height measurement value H1 of the ultrasonic liquid surface sensor is obtained, where the liquid surface distance h is the distance from the sensor to the liquid surface;

[0018] Keeping the liquid surface distance h constant, the actual value H0 of the liquid surface height of the corresponding ultrasonic liquid surface sensor is obtained when the liquid surface is stationary.

[0019] Calculate the correction value H for different water mist thicknesses d and liquid flow velocities v under the same liquid surface distance h, where H = H0 - H1.

[0020] Preferably, the liquid surface distance h is adjustable in the range of 0.1m-2.5m, the water mist thickness d is adjustable in the range of 0-100mm, and the liquid flow rate v is adjustable in the range of 0-10m / s.

[0021] The ultrasonic liquid level sensor testing platform provided by this invention includes a flow pump and an atomizer that can adjust the liquid flow rate and water mist thickness in the water tank to simulate different liquid level conditions. The platform can measure the liquid level height of the ultrasonic liquid level sensor under various liquid level distances h, in a static state, and under different liquid level conditions through orthogonal experiments. This allows for the acquisition of correction values ​​for the ultrasonic liquid level sensor under different liquid level distances h and liquid level conditions, thereby compensating for measurement errors caused by the working environment in actual dynamic measurements and improving the accuracy of liquid level height measurement in mud tanks.

[0022] Furthermore, this invention also provides a test calibration method using the aforementioned ultrasonic liquid level sensor test platform. This method can compensate for measurement errors caused by water mist and liquid level fluctuations in actual dynamic measurements through calibration values, thereby improving the accuracy of mud tank liquid level height measurement and ensuring the accuracy of drilling fluid total volume change, thus guaranteeing downhole and surface construction safety. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0024] Figure 1 A schematic diagram of a specific embodiment of the ultrasonic liquid level sensor testing platform provided by the present invention;

[0025] Figure 2 This is a partial structural diagram of the lifting and adjusting mechanism.

[0026] Figures 1-2 middle:

[0027] 1-Test stand; 11-Pulley; 2-Water tank; 21-Water tank splash guard; 3-Atomizer; 4-Flow pump pipeline; 5-Flow pump; 6-Slide assembly; 61-Servo motor; 62-Reducer; 63-Gear; 64-Gear belt; 65-Slide base; 7-Instrument mounting plate; 8-Ultrasonic liquid level sensor; 9-Control box. Detailed Implementation

[0028] 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.

[0029] The core of this invention is to provide an ultrasonic liquid level sensor testing platform that can obtain the correction values ​​of the ultrasonic liquid level sensor under different liquid level distances h and liquid level conditions, so as to compensate for the influence of the working environment on the accuracy of liquid level measurement.

[0030] In addition, the present invention also provides a test calibration method using the above-mentioned ultrasonic liquid level sensor test platform.

[0031] The ultrasonic liquid level sensor testing platform provided by this invention includes a test frame 1 and a control device. The test frame 1 is provided with a water tank 2, an atomizer 3 and an ultrasonic liquid level sensor 8 to be tested, arranged sequentially from bottom to top. The water tank 2 is connected to a flow pump 5 to adjust the liquid flow rate v in the water tank 2. The atomizer 3 is provided in the water tank 2 to adjust the water mist thickness d of the liquid surface. The ultrasonic liquid level sensor 8 is connected to the test frame 1 through a lifting adjustment mechanism. The lifting adjustment mechanism is used to adjust the liquid surface distance h from the ultrasonic liquid level sensor 8 to the liquid surface. The flow pump 5, the atomizer 3 and the lifting adjustment mechanism are all signal connected to the control device.

[0032] The test frame 1 is equipped with a water tank 2 and an ultrasonic liquid level sensor 8 to be tested, which is used to simulate the liquid level detection environment of the mud tank. The test frame 1 is preferably set as a frame structure or a frame plate structure. The test frame 1 is usually welded from steel plates and steel pipes, which has a simple structure and low cost.

[0033] To facilitate the movement of the test frame 1, the bottom of the test frame 1 is usually equipped with pulleys 11. The height of the pulleys 11 is adjustable to ensure that the base of the test frame 1 is in a horizontal state. At the same time, the pulleys 11 have a self-locking function to prevent the test frame 1 from moving relative to the ground after it has been moved into place.

[0034] The material, shape, structure, and size of the test frame 1, as well as the number, material, and type of pulleys 11, are determined based on the actual production needs and with reference to existing technologies, and will not be elaborated here.

[0035] Water tank 2 is located at the bottom of test frame 1 to facilitate the filling, emptying and cleaning of water tank 2. The type and composition of drilling fluid in water tank 2 are based on the type and composition of drilling fluid in mud tank in actual production, so as to accurately obtain the correction value of the liquid level height measurement of the ultrasonic liquid level sensor 8 to be tested.

[0036] Water tank 2 is connected to flow pump 5 via flow pump pipeline 4. Flow pump 5 is used to adjust the liquid flow rate v in water tank 2. The adjustment range of liquid flow rate v is determined according to the flow rate of drilling fluid in mud tank during actual production. The type, power and connection method of flow pump 5 and flow pump pipeline 4 are determined according to the needs of actual production and with reference to existing technology, and will not be elaborated here.

[0037] The water tank 2 is equipped with an atomizer 3, which is used to produce water mist. The thickness d of the water mist above the liquid surface can be adjusted by adjusting the power of the atomizer 3. The maximum power of the atomizer 3 needs to be determined based on the thickness of the drilling fluid in the mud tank and the volume of liquid in the water tank 2 during actual production.

[0038] The ultrasonic liquid level sensor 8 under test is connected to the test frame 1 through a lifting adjustment mechanism. The lifting adjustment mechanism is used to adjust the liquid level distance h from the ultrasonic liquid level sensor 8 to the liquid surface. The lifting adjustment mechanism can be set as a linear motor, electric push rod, etc., or it can be raised and lowered along the height direction by using a servo motor 61 through a belt drive mechanism or a gear rack mechanism.

[0039] The control device is used to control the working status of the flow pump 5, the atomizer 3 and the lifting adjustment mechanism. The control device can be connected to the above-mentioned actuators via cables, or via wireless, WiFi signals or other means.

[0040] The controllers for controlling the flow pump 5, the atomizer 3, and the lifting adjustment mechanism can be set up individually or integrated into the same control box 9. Please refer to [reference needed]. Figure 1 The control device includes a control box 9, which contains a wireless receiver. The control box 9 can control the rotation of the servo motor 61 of the lifting and adjusting mechanism via wired or wireless means.

[0041] In this embodiment, the flow pump 5 and the atomizer 3 can respectively adjust the liquid flow rate and water mist thickness in the water tank 2 to simulate different liquid surface conditions. The liquid level height of the ultrasonic liquid level sensor 8 under various liquid surface distances h, in a static state, and under different liquid surface conditions can be measured by orthogonal experiment. The correction values ​​of the ultrasonic liquid level sensor 8 under different liquid surface distances h and liquid surface conditions can be obtained, thereby compensating for the measurement error caused by the working environment in actual dynamic measurement and improving the measurement accuracy of the liquid level height in the mud tank.

[0042] Preferably, in order to facilitate the layout of the flow pump 5 and the control device, the side of the test frame 1 is provided with a protruding lateral mounting plate, and a diagonal bracing beam is provided between the lateral mounting plate and the test frame 1 to enhance the connection stability between the lateral mounting plate and the test frame 1, and both the flow pump 5 and the control device are located on the lateral mounting plate.

[0043] Based on the above embodiments, the structure of the lifting adjustment mechanism is further defined. The lifting adjustment mechanism includes a gear belt 64 arranged along the height direction. The gear belt 64 is connected to the ultrasonic liquid level sensor 8. The upper and lower ends of the gear belt 64 are respectively sleeved on the gear 63. The gear 63 at one end of the gear belt 64 is connected to the servo motor 61. When the servo motor 61 rotates, the gear 63 drives the gear belt 64 to move up and down along the height direction, and drives the ultrasonic liquid level sensor 8 to move up and down along the height direction.

[0044] Please refer to Figure 2 Gear 63 is rotatably located at the upper and lower ends of the slide housing of the slide assembly 6. The slide housing can be connected to the test frame 1 by fastening bolts or connecting pins, or welded to the test frame 1. Preferably, the slide housing is provided with scale markings so as to quickly obtain the height of the slide base 65 and the ultrasonic liquid level sensor 8.

[0045] The gear belt 64 is fitted between the gears 63 at both ends. The gear belt 64 is connected to the slide base 65. The slide base 65 is connected to the horizontally set instrument mounting plate 7. The ultrasonic liquid level sensor 8 is installed on the instrument mounting plate 7.

[0046] To prevent the ultrasonic liquid level sensor 8 from shifting during the lifting and lowering process and affecting its measurement results, the instrument mounting plate 7 can be fixedly connected to the sensor bracket of the ultrasonic liquid level sensor 8 using fasteners such as bolts and connecting pins.

[0047] When the servo motor 61 drives the gear 63 to rotate, the gear 63 drives the gear belt 64 to rotate, which in turn drives the slide base 65 to rise and fall in the height direction, thereby driving the instrument mounting plate 7 and the ultrasonic liquid level sensor 8 to rise and fall in the height direction.

[0048] In this embodiment, compared with the synchronous belt drive mechanism, the gear belt drive mechanism has higher transmission accuracy and is more conducive to accurately adjusting and controlling the height of the ultrasonic liquid level sensor 8, thereby adjusting the liquid surface distance h from the ultrasonic liquid level sensor 8 to the liquid surface.

[0049] Considering that the servo motor 61 has a relatively high speed, the servo motor 61 is usually connected to the gear 63 through the reducer 62 in order to reduce the speed of the servo motor 61 and amplify the torque. The reducer 62 preferably has a locking capability.

[0050] Considering the center of gravity and stability of the lifting adjustment mechanism, the servo motor 61 is usually located at the bottom of the lifting adjustment mechanism, which makes the servo motor 61, reducer 62 and gear 63 close to the liquid surface, causing drilling fluid to easily splash into the lifting adjustment mechanism and affect its lifespan.

[0051] To prevent liquid from splashing into the lifting and adjusting mechanism, preferably, the lifting and adjusting mechanism can be set on one side of the test frame 1, and the water tank 2 is provided with a water tank splash guard 21 that is higher than the liquid level. The water tank splash guard 21 is used to prevent liquid from splashing into the lifting and adjusting mechanism.

[0052] The material of the water tank splash guard 21 is not limited, as long as it has good waterproof performance, processing performance and chemical stability. The water tank splash guard 21 is preferably made of the following material. Figure 1 The L-shaped plate shown has two functions: firstly, the vertical plate of the water tank splash guard 21 can prevent liquid from splashing into the lifting and adjusting mechanism from the side; secondly, the horizontal plate of the water tank splash guard 21 can prevent liquid from splashing into the lifting and adjusting mechanism from the bottom.

[0053] The splash guard 21 of the water tank is positioned above the liquid level in the water tank 2. The height of the splash guard 21 above the liquid level should be greater than the maximum liquid flow velocity v. max The maximum splash height of the liquid is set to ensure that the liquid will not splash into the lifting and adjusting mechanism during the test. Of course, in order to extend the life of the lifting and adjusting mechanism, the liquid in the water tank 2 needs to be drained after the test.

[0054] The portion of the water tank splash guard 21 located inside the water tank 2 is fixed to the inner wall of the water tank 2, while the portion of the water tank splash guard 21 that extends above the water tank 2 is fixedly connected to the test frame 1. Due to sealing requirements, it is not advisable to drill holes in the inner wall of the water tank 2. The water tank splash guard 21 is preferably fixed inside the water tank 2 by interference fit or adhesive bonding. The water tank splash guard 21 and the test frame 1 can be connected by common fasteners such as bolts and connecting pins.

[0055] In this embodiment, the water tank splash guard 21 prevents liquid from entering the lifting adjustment mechanism, effectively slowing down the corrosion and aging process of the internal components of the lifting adjustment mechanism and improving the service life of the lifting adjustment mechanism.

[0056] In addition to the ultrasonic liquid level sensor test platform described above, this invention also provides a test calibration method using the ultrasonic liquid level sensor test platform disclosed in the above embodiments. This test calibration method includes:

[0057] By controlling the liquid surface distance h, water mist thickness d, and liquid flow velocity v through orthogonal experiments, the liquid surface height measurement value H1 of the ultrasonic liquid surface sensor 8 is obtained, where the liquid surface distance h is the distance from the sensor to the liquid surface.

[0058] Keeping the liquid surface distance h constant, the actual value H0 of the liquid surface height corresponding to the ultrasonic liquid surface sensor 8 is obtained when the liquid surface is stationary.

[0059] Calculate the correction value H for different water mist thicknesses d and liquid flow velocities v under the same liquid surface distance h, where H = H0 - H1.

[0060] It should be noted that the adjustment range and precision of the three variables—liquid surface distance h, water mist thickness d, and liquid flow velocity v—in the orthogonal experiment were determined based on the working environment of the mud tank liquid level alarm or monitoring device in actual production.

[0061] For example, based on the sensor settings and liquid level range in the mud tank during actual production, the adjustment range of the liquid level height h is usually set to 0.1m-2.5m. However, based on the actual water vapor and liquid level fluctuations, the adjustment range of the water mist thickness d is often set to 0-100mm, and the adjustment range of the liquid flow velocity v is set to 0-10m / s.

[0062] In this embodiment, without changing the existing equipment conditions of the ultrasonic liquid level sensor 8 and without stopping on-site construction operations such as the circulating pump and agitator, the measurement error caused by water mist and liquid level fluctuations in actual dynamic measurement can be compensated by the correction value H, thereby improving the measurement accuracy of the liquid level height in the mud tank, ensuring the accuracy of the change in the total volume of drilling fluid, and ensuring the safety of downhole and surface construction.

[0063] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0064] The ultrasonic liquid level sensor testing platform and testing and calibration method provided by this invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. It should be noted that those skilled in the art can make several improvements and modifications to this invention without departing from the principles of this invention, and these improvements and modifications also fall within the protection scope of the claims of this invention.

Claims

1. An ultrasonic liquid level sensor testing platform, characterized in that, The test includes a test frame (1) and a control device. The test frame (1) is provided with a water tank (2), an atomizer (3) and an ultrasonic liquid level sensor (8) to be tested, arranged from bottom to top. The water tank (2) is connected to a flow pump (5) to adjust the liquid flow rate v in the water tank (2). The atomizer (3) is provided in the water tank (2) to adjust the water mist thickness d of the liquid surface. The ultrasonic liquid level sensor (8) is connected to the test frame (1) through a lifting adjustment mechanism. The lifting adjustment mechanism is used to adjust the liquid surface distance h from the ultrasonic liquid level sensor (8) to the liquid surface. The flow pump (5), the atomizer (3) and the lifting adjustment mechanism are all connected to the control device.

2. The ultrasonic liquid level sensor testing platform according to claim 1, characterized in that, The lifting adjustment mechanism includes a gear belt (64) arranged along the height direction. The gear belt (64) is connected to the ultrasonic liquid level sensor (8). The upper and lower ends of the gear belt (64) are respectively sleeved on the gear (63). The gear (63) at one end of the gear belt (64) is connected to the servo motor (61). When the servo motor (61) rotates, the gear (63) drives the gear belt (64) to rise and fall along the height direction, and drives the ultrasonic liquid level sensor (8) to rise and fall along the height direction.

3. The ultrasonic liquid level sensor testing platform according to claim 2, characterized in that, The gear (63) is rotatably mounted on the upper and lower ends of the slide housing. The gear belt (64) is connected to the slide base (65). The slide base (65) is connected to the horizontally set instrument mounting plate (7). The ultrasonic liquid level sensor (8) is mounted on the instrument mounting plate (7).

4. The ultrasonic liquid level sensor testing platform according to claim 2, characterized in that, The servo motor (61) is connected to the gear (63) via a reducer (62), and the reducer (62) has a locking function.

5. The ultrasonic liquid level sensor testing platform according to claim 2, characterized in that, The control device includes a control box (9), which is equipped with a wireless receiver. The control box (9) can control the rotation of the servo motor (61) via wired or wireless means.

6. The ultrasonic liquid level sensor testing platform according to any one of claims 1-5, characterized in that, The lifting adjustment mechanism is located on one side of the test frame (1), and the water tank (2) is provided with a water tank splash guard (21) higher than the liquid level. The water tank splash guard (21) is used to prevent liquid from splashing into the lifting adjustment mechanism.

7. The ultrasonic liquid level sensor testing platform according to any one of claims 1-5, characterized in that, The test frame (1) has a protruding lateral mounting plate on its side, and a diagonal bracing beam is provided between the lateral mounting plate and the test frame (1). The flow pump (5) and the control device are both located on the lateral mounting plate.

8. The ultrasonic liquid level sensor testing platform according to any one of claims 1-5, characterized in that, The test frame (1) is provided with height-adjustable pulleys (11) at the bottom, and the pulleys (11) have a locking function.

9. A testing and calibration method, using the ultrasonic liquid level sensor testing platform according to any one of claims 1-8, characterized in that, include: By controlling the liquid surface distance h, water mist thickness d and liquid flow velocity v through orthogonal experiment, the liquid surface height measurement value H1 of the ultrasonic liquid surface sensor (8) is obtained, where the liquid surface distance h is the distance from the sensor to the liquid surface; Keep the liquid surface distance h constant, and obtain the actual value H0 of the liquid surface height of the corresponding ultrasonic liquid surface sensor (8) when the liquid surface is stationary; Calculate the correction value H for different water mist thicknesses d and liquid flow velocities v under the same liquid surface distance h, where H = H0 - H1.

10. The test calibration method according to claim 9, characterized in that, The adjustment range of the liquid surface distance h is 0.1m-2.5m, the adjustment range of the water mist thickness d is 0-100mm, and the adjustment range of the liquid flow rate v is 0-10m / s.

Images