Analog sensor and calibration device and calibration method thereof

Abstract

The present invention discloses an analog sensor calibration device, comprising: a modulation module for modulating and generating a voltage-modulated signal containing calibration instructions, and transmitting the voltage-modulated signal to the power supply terminal of the analog sensor; a receiving module for receiving the calibration output fed back by the analog sensor; and a control module for determining whether the calibration is successful based on the calibration instructions and the calibration output. This device allows calibration after the sensor is fully assembled, improving sensor production efficiency, accuracy, and yield, as well as the sensor's maintainability in the future.

Description

Technical Field

[0001] The present invention relates to a sensor, in particular to an analog sensor and a calibration device and a calibration method thereof. Background Art

[0002] Analog sensors emit continuous analog signals, generally using voltage, current, etc. to represent the size of the measured parameter. The output analog signal can be a 4-20mA current signal, or a 0-5V, 0-10V voltage signal.

[0003] Currently, analog sensors are typically calibrated prior to assembly using a reserved internal digital communication interface (TTL, 485). After calibration, the sensors are packaged, for example, using a potting process. This packaging process typically minimizes external interfaces on the sensor to enhance its protection level, such as two power cords and two output lines. This packaged sensor is waterproof, dustproof, and explosion-proof, making it highly durable and suitable for a wide range of applications. For example, it can be used in products with high protection requirements, such as explosion-proof equipment for mines. However, packaged analog sensors cannot be recalibrated after assembly, significantly complicating their production and calibration, impacting sensor accuracy and the yield rate of the finished product. Summary of the Invention

[0004] In view of the defects of the prior art, the present invention provides an analog sensor and a calibration device and a calibration method thereof.

[0005] An analog quantity sensor comprises: a power supply module for receiving a modulated voltage modulation signal containing a calibration instruction; a demodulation module for demodulating the voltage modulation signal to obtain the calibration instruction; a processing module for obtaining a corresponding calibration output according to the calibration instruction; and an output module for outputting the calibration output.

[0006] Optionally, the power supply module includes a first output and a second output, wherein the first output is used for the working voltage of the sensor, and the second output is the voltage modulation signal; the voltage modulation signal is composed of a start signal and a data signal encoding.

[0007] An analog sensor calibration device includes: a modulation module for modulating to generate a voltage modulation signal containing a calibration instruction and sending the voltage modulation signal to the power supply terminal of the analog sensor; a receiving module for receiving the calibration output fed back by the analog sensor; and a control module for determining whether the calibration is successful based on the calibration instruction and the calibration output.

[0008] Optionally, it also includes: an input module for inputting the calibration instruction; when the received calibration output is consistent with the sent calibration instruction, the calibration is determined to be successful, otherwise, the calibration is determined to be failed; the voltage modulation signal is composed of a start signal and a data signal encoding; the start signal is used to indicate the start of calibration; the data signal indicates the current calibration status, including zero point calibration, mid-point calibration and full-scale calibration; the start signal is a pulse width signal composed of high and low levels, and the data signal is a pulse width signal composed of a reference level.

[0009] A method for calibrating an analog sensor comprises the following steps: S100: modulating to generate a voltage modulation signal containing a calibration instruction, and sending the voltage modulation signal to the power supply terminal of the analog sensor; S200: receiving a calibration output fed back by the analog sensor; and S300: determining whether the calibration is successful based on the calibration instruction and the calibration output.

[0010] The beneficial effects of the present invention are as follows: the present invention provides an analog signal output type sensor and its calibration device and method, which encodes a specific voltage timing waveform through a voltage regulating module and outputs it to the sensor. When the sensor receives and decodes the "instruction", the sensor outputs a timing signal and feeds it back to the calibration device, and then displays the current calibration status through the display module. Finally, different buttons are used to encode calibration zero point, midpoint, full point and other instructions, thereby achieving the purpose of calibrating the sensor. In addition, the device and method can also realize the sensor's range setting, deviation adjustment and other functions, which are equivalent to the effect of "communication" with the sensor.

[0011] The calibration device and method for analog signal output sensors can be used to calibrate 4-20mA, 0-5V, and 0-10V signal sensors. Without changing the original sensor appearance and wiring harness, it solves the defect that analog signal sensors cannot be calibrated through digital communication interfaces, greatly improves the production accuracy, production convenience, and applicability of the sensor, and realizes the effect of "communication" with analog signal sensors.

[0012] The device and method of this invention can effectively replace the TTL or 485 interface to achieve "communication", and calibration can be performed after the sensor is fully assembled, thereby improving the sensor production efficiency, accuracy and yield rate as well as the sensor's later maintainability. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a schematic diagram of the external wiring between the calibration end and the sensor end;

[0014] Figure 2 Schematic diagram of the internal structure of the calibration end and the sensor end;

[0015] Figure 3This is the waveform diagram of the start signal;

[0016] Figure 4 This is the waveform diagram of the zero point calibration voltage modulation signal;

[0017] Figure 5 The waveform diagram of the voltage modulation signal is used to calibrate the midpoint;

[0018] Figure 6 This is the waveform diagram of the full-scale calibration voltage modulation signal;

[0019] Figure 7 Flowchart of the calibration method. DETAILED DESCRIPTION

[0020] To make the above-mentioned objects, features, and advantages of the present invention more readily apparent, the following detailed description of specific embodiments of the present invention is provided in conjunction with the accompanying drawings, so that the above-mentioned and other objects, features, and advantages of the present invention will become more apparent. Like reference numerals denote like parts throughout the drawings. The drawings are not drawn to scale; emphasis is placed on illustrating the subject matter of the present invention.

[0021] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used by the inventor to enable a clear and consistent understanding of the invention. Therefore, it will be apparent to those skilled in the art that the following description of various embodiments of the invention is provided for illustration purposes only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

[0022] It should be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "module" includes reference to one or more of such modules. The advantages and features of the present invention and methods of accomplishing the same may be more readily understood by reference to the detailed description of the embodiments below and the accompanying drawings. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concepts of the invention to those skilled in the art.

[0023] Example 1

[0024] See Figure 1The calibration system of the present invention may include a calibration end and a sensor end, and the calibration end is connected to the sensor end. The calibration end may be a handheld operating end, which has a shell made of, for example, metal or plastic material, and is provided with, for example, an LED display, indicator lights, various buttons, etc. on the shell. In addition, the shell also has a voltage signal output port and an analog signal receiving port. The operating end can be connected to the voltage signal interface of the sensor end through the voltage signal output port, and connected to the analog signal output port of the sensor end through the signal receiving port. The shell of the handheld operating end may have a processing circuit composed of integrated components or discrete components, preferably a PCB board composed of integrated circuits, which is conducive to the miniaturization of the calibration end. The LED display, indicator lights, various buttons, various interfaces, etc. on the shell are all connected to the PCB board, and the operation of each component is controlled by the PCB board.

[0025] like Figure 2 As shown, the calibration end can include a control module, a modulation module, and a receiving module. In addition to the above modules, it can also include, for example, a display module, an input module, etc., and can further include, for example, various data storage modules. The control module is the core of the calibration end and is connected to each of the other modules. The control module connects the modulation module and the receiving module. The control module controls the modulation module to output different voltage modulation signals containing calibration instructions according to the control instructions. This voltage modulation signal is sent to the power input port of the sensor end. The sensor end uses this voltage modulation signal as its operating power supply and performs corresponding calibration output according to the calibration instructions in the voltage modulation signal. The receiving module is used to receive the calibration output of the sensor and send it to the control module. The control module can determine whether the corresponding calibration instruction has been executed by the sensor end based on this received calibration output, and then determine whether the corresponding calibration has been completed.

[0026] The display module can include various LED indicators, liquid crystal displays, etc., which indicate the current working status of the calibration terminal through the indicators or displays. For example, the display can display the currently input calibration instruction, or the indicator light can indicate the current calibration status (such as zero point calibration, midpoint calibration, full-scale calibration, etc.). The input module can be various physical or virtual buttons. Through the input module, the user can input different calibration instructions to the calibration terminal. After receiving the calibration instruction, the control module sends it to the modulation module. The modulation module adds the calibration instruction to the voltage supplying the sensor terminal, thereby forming a voltage modulation signal.

[0027] The sensor end of the present invention is described in detail below. The sensor end includes a power module, a demodulation module, a processing module, and an output module. In addition to the above modules, the sensor end may also include, for example, a detection module for implementing different detection functions of the sensor, a signal processing module for processing the detected signals, and a storage module for data storage. The power module can have two different outputs, the first outputting a stable operating voltage and the second outputting a voltage modulated signal. The first output is connected to the demodulation module, the processing module, and the output module respectively. In addition, the first output can also be connected to the detection module, the signal processing module, and the storage module. The first output provides a stable operating voltage to the sensor end, ensuring that the sensor can operate stably.

[0028] The second output is connected to the demodulation module, which demodulates the received voltage modulation signal, demodulates the calibration instruction from it and sends the instruction to the processing module. The processing module controls the output module to perform corresponding calibration output according to the demodulated calibration instruction. This calibration output is sent to the calibration end. If the calibration end determines that the received calibration output is consistent with the sent calibration instruction, the calibration is considered to be successful. Otherwise, the calibration is considered to have failed. In this way, the calibration end can calibrate the sensor end based on the calibration output fed back.

[0029] Specifically, the voltage modulation signal of the present invention is composed of a start signal and a data signal. The data signal follows the start signal and indicates the start of calibration. Upon receiving the start signal, the sensor enters the calibration state. The data signal indicates the current calibration state, which can represent zero-point calibration, mid-point calibration, or full-scale calibration. Upon receiving the data signal in the calibration state, the sensor performs the corresponding calibration output based on the data signal.

[0030] Figure 3 The start signal used in the present invention is shown. This start signal is composed of a series of high and low level voltage signals. Figure 3 The low and medium levels have a voltage of 10V and a pulse width of 1S, while the high level has a voltage of 12V and a pulse width of 1S. After receiving this start signal, the calibration end enters the calibration state.

[0031] The present invention uses a reference voltage signal with different pulse widths to represent the data signal. The voltage value of this reference voltage signal is between the high and low levels of the start signal. Figure 4 As shown in FIG, after the start signal is a level signal with a 2S pulse width and a voltage value of 11V, this signal represents the data signal used for calibration, specifically, for example, it can represent zero point calibration. Figure 5In the example, the start signal is followed by a level signal with a 3S pulse width and a voltage value of 11V. This signal represents the data signal used for calibration. Specifically, it can represent the midpoint calibration. Figure 6 In the example, the start signal is followed by a level signal with a pulse width of 4S and a voltage value of 11V. This signal represents a data signal used for calibration. Specifically, for example, it can represent full-scale calibration.

[0032] The following is combined with Figure 2 To the attached Figure 6 The calibration process is described in more detail. For example, the calibration terminal output signal is 0-5V. Its zero-point output voltage is 0V, its midpoint output voltage is 2.5V, and its full-scale output voltage is 5V. The calibration terminal supports a wide voltage input range, typically 10-30VDC or even wider. The calibration terminal also has a built-in ADC function that can measure the power supply input voltage.

[0033] When zero point calibration is to be performed, the calibration terminal inputs the zero point calibration instruction through the input module. After the control module receives the instruction, it controls the modulation module to modulate the output voltage signal and modulate it into Figure 4 The power module detects the input voltage through the ADC and demodulates the input signal. When a low level of 10V and a level of 12V are detected, the module enters the calibration state and then times the reference level. If the reference level time is 2s, the processing module controls the output module to output 0V voltage to the receiving module at the calibration end. If the calibration output of 0V received is consistent with the calibration instruction (zero point calibration) sent by the calibration end, the calibration is considered successful. Otherwise, the calibration is considered failed.

[0034] When the midpoint calibration is to be performed, the calibration end inputs the midpoint calibration instruction through the input module. After the control module receives the instruction, it controls the modulation module to modulate the output voltage signal and modulate it into Figure 5 The power module detects the input voltage through the ADC and demodulates the input signal. When a low level of 10V and a level of 12V are detected, the power module enters the calibration state and then times the reference level. If the reference level time is 3s, the processing module controls the output module to output a 2.5V voltage to the receiving module at the calibration end. If the calibration output of 2.5V received is consistent with the calibration instruction sent (midpoint calibration), the calibration is considered successful. Otherwise, the calibration is considered failed.

[0035] When full-scale calibration is required, the calibration terminal inputs the zero-point calibration instruction through the input module. After the control module receives this instruction, it controls the modulation module to modulate the output voltage signal and modulate it into Figure 6 The power module detects the input voltage through the ADC and demodulates the input signal. When a low level of 10V and a level of 12V are detected, the power module enters the calibration state and then times the reference level. If the reference level time is 4s, the processing module controls the output module to output a 5V voltage to the receiving module at the calibration end. If the calibration output of 5V received is consistent with the calibration instruction sent (full-scale calibration), the calibration is considered successful. Otherwise, the calibration is considered failed.

[0036] This invention encodes the sensor's supply voltage and outputs the corresponding voltage waveform according to a specific protocol, enabling "communication" between the device and the sensor, achieving calibration and parameter setting. It is suitable for calibrating various sensors that output analog signals, offering high practicality, a wide range of applications, and a quick and convenient design.

[0037] Example 2

[0038] Correspondingly, such as Figure 7 As shown, the present invention also provides an analog sensor calibration method, comprising the following steps:

[0039] S100: Modulating to generate a voltage modulation signal including a calibration instruction, and sending the voltage modulation signal to a power supply terminal of the analog sensor;

[0040] S200: receiving a calibration output fed back by the analog sensor;

[0041] S300: Determine whether the calibration is successful according to the calibration instruction and the calibration output.

[0042] Step S300 specifically includes: when the received calibration output is consistent with the sent calibration instruction, determining that the calibration is successful; otherwise, determining that the calibration is failed.

[0043] The above-mentioned voltage modulation signal is composed of a start signal and a data signal encoding; the start signal is used to indicate the start of calibration; the data signal indicates the current calibration status, including zero point calibration, midpoint calibration and full-scale calibration; the start signal is a pulse width signal composed of high and low levels, and the data signal is a pulse width signal composed of a reference level.

[0044] Although the technology has been illustrated and described with respect to one or more embodiments, changes and / or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In particular, with respect to the various functions performed by the components or structures (assemblies, devices, circuits, systems, etc.) described above, terms used to describe such components (including references to "means") are intended to correspond to any component or structure that performs the designated function of the described component (e.g., functionally equivalent), even if not structurally equivalent to the disclosed structure that performs the function in the example embodiments described herein, unless otherwise indicated. In addition, although a particular feature may have been disclosed with respect to one embodiment among several embodiments, such feature may be combined with one or more other features in other embodiments as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms "comprising," "including," "having," "having," "containing," or variations thereof are used in the detailed description or claims, such terms are intended to be inclusive in a manner similar to the term "comprising."

[0045] In the above description, many specific details are set forth in order to fully understand the present invention. However, the above description is only a preferred embodiment of the present invention. The present invention can be implemented in many other ways different from those described herein, so the present invention is not limited to the specific implementation disclosed above. At the same time, any person skilled in the art can make many possible changes and modifications to the technical solution of the present invention using the methods and technical contents disclosed above without departing from the scope of the technical solution of the present invention, or modify it into an equivalent embodiment of equivalent changes. Any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still falls within the scope of protection of the technical solution of the present invention.

Claims

1. An analog sensor calibration device, characterized in that: include: A modulation module is used to modulate and generate a voltage modulation signal containing a calibration instruction, and send the voltage modulation signal to the power supply terminal of the analog sensor; The voltage modulation signal is composed of a start signal and a data signal encoding; the start signal is used to indicate the start of calibration; the data signal indicates the current calibration status, including zero point calibration, midpoint calibration and full scale calibration; the start signal is a pulse width signal composed of high and low levels, and the data signal is a pulse width signal composed of a reference level; The data signal is located after the start signal, and the start signal is composed of a series of high and low level voltage signals. After receiving the start signal, the analog sensor calibration device enters the calibration state and uses a reference voltage signal with different pulse widths to represent the data signal. The voltage value of the reference voltage signal is between the high and low levels of the start signal; A receiving module, configured to receive the calibration output fed back by the analog sensor; a control module, configured to determine whether the calibration is successful based on the calibration instruction and the calibration output; if the received calibration output is consistent with the sent calibration instruction, the calibration is determined to be successful; otherwise, the calibration is determined to be unsuccessful; An input module, used for inputting the calibration instruction; In addition, the analog sensor specifically includes: A power module, configured to receive a modulated voltage modulation signal containing a calibration instruction; the power module comprises a first output and a second output, wherein the first output is used for the operating voltage of the sensor, and the second output is the voltage modulation signal; A demodulation module, configured to demodulate the voltage modulation signal to obtain the calibration instruction; A processing module, configured to obtain a corresponding calibration output according to the calibration instruction; An output module is used to output the calibration output.

2. An analog sensor calibration method for the analog sensor calibration device of claim 1, characterized in that: The following steps are involved: S100: Modulating to generate a voltage modulation signal including a calibration instruction, and sending the voltage modulation signal to a power supply terminal of the analog sensor; S200: receiving a calibration output fed back by the analog sensor; S300: Determine whether the calibration is successful according to the calibration instruction and the calibration output.

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