Diaphragm pump oil replenishment and discharge detection system and oil replenishment and discharge control method

Abstract

The present invention discloses a diaphragm pump oil replenishment and discharge detection system and an oil replenishment and discharge control method. The diaphragm pump oil replenishment and discharge detection system includes a diaphragm and a diaphragm guide rod. The diaphragm divides the inner cavity of the pump body into a hydraulic oil chamber and a medium chamber; a first inductive sensor and a second inductive sensor are arranged in the hydraulic chamber; the diaphragm guide rod is a metal guide rod, which can successively approach the first inductive sensor and the second inductive sensor during reciprocating movement; the first inductive sensor and the second inductive sensor are both long-distance pressure-resistant inductive sensors; when the diaphragm guide rod approaches the first inductive sensor and the second inductive sensor and is within the sensing distance of the first inductive sensor and the second inductive sensor, the first inductive sensor and the second inductive sensor can be triggered successively within a certain period of time and output switching quantities to a controller.

Description

Technical Field

[0001] The present invention relates to the field of hydraulic water pumps, and in particular to a diaphragm pump oil replenishment and discharge detection system and an oil replenishment and discharge control method. Background Art

[0002] Existing diaphragm pumps primarily employ two control modes: mechanical oil replenishment and discharge control, and electromagnetic oil replenishment and discharge control. Both require manual setting of oil replenishment or discharge limit positions. A replenishment probe (or mechanical oil replenishment valve) determines the diaphragm's oil replenishment starting point, while a discharge probe (or mechanical oil discharge valve) determines the diaphragm's oil discharge starting point. During detection, a permanent magnet ring is mounted on the diaphragm's guide rod. An electromagnetic proximity switch acts as a probe to detect the ring's magnetic field strength. When the magnetic field reaches the probe's set threshold, a switch signal is output to the oil replenishment and discharge control system, thereby automatically replenishing or draining oil. The electromagnetic diaphragm position detection mechanism described above has the following major drawbacks: 1. The permanent magnet ring carries the risk of demagnetization, especially in high-temperature environments, where magnetic attenuation is more severe. 2. The permanent magnet ring's supporting components must be made of non-magnetic, non-magnetic steel; otherwise, the magnetic field strength received by the electromagnetic proximity switch will be affected, resulting in distorted output signals. 3. Both the permanent magnet ring and non-magnetic steel are brittle materials with high hardness and low machinability. Summary of the Invention

[0003] In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to provide a diaphragm pump oil replenishment and discharge detection system and an oil replenishment and discharge control method to solve the problems of unstable output signals and impaired performance in high temperature environments in the existing diaphragm pump oil replenishment and discharge detection system.

[0004] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0005] A diaphragm pump oil replenishment and discharge detection system includes a diaphragm pump, a diaphragm is provided in the diaphragm pump, the diaphragm divides the inner cavity of the pump body into a hydraulic oil chamber and a medium chamber, a diaphragm guide rod is provided in the middle of the diaphragm, one end of the diaphragm is connected to the diaphragm, the other end extends into the hydraulic oil chamber and is arranged horizontally, the diaphragm guide rod can move axially repeatedly in the hydraulic oil chamber; a first inductive sensor and a second inductive sensor are provided in the hydraulic chamber, and there is a gap between the first inductive sensor and the second inductive sensor and the outer end surface of the diaphragm guide rod; the diaphragm guide rod is a cylindrical guide rod made of metal, which can successively approach the first inductive sensor and the second inductive sensor in the reciprocating movement. The second inductive sensor is a long-distance, pressure-resistant inductive sensor with a detection range of 0.1 to 15 mm. When the diaphragm guide rod approaches the first and second inductive sensors and is within their sensing range, the first and second inductive sensors are triggered sequentially within a certain timeframe and output switching values ​​to a controller. The controller, upon receiving the switching values ​​from the first and second inductive sensors, determines the oil level in the hydraulic oil chamber based on a predetermined determination rule. Thus, the inductive sensor is heat-resistant and adaptable to the high-temperature environment of the hydraulic oil chamber. It also has a long sensing range and is suitable for sensing the position of the diaphragm guide rod in various operating conditions. Furthermore, compared to traditional electromagnetic sensors, inductive sensors offer a simpler and more reliable detection principle, stronger anti-interference capabilities, and effectively avoid the risk of demagnetization due to high temperatures. They also have the advantages of a long service life and a stable output signal. The diaphragm guide rod is made of metal to accommodate the magnetic field sensing of the inductive sensor. After the inductive sensor used outputs switching information, the controller will make a judgment according to the corresponding judgment rules. The judgment logic is highly compatible with the existing control system and does not require a large amount of engineering application verification, so it can be quickly promoted.

[0006] Furthermore, the first and second inductive sensors are both arranged vertically, with the diaphragm guide rod located below the first and second inductive sensors. Thus, the two inductive sensors are spaced apart, enabling determination of the diaphragm guide rod end entry at both short and long distances.

[0007] Furthermore, the first inductive sensor is vertically positioned above the diaphragm guide rod, while the second inductive sensor is horizontally positioned, with its centerline overlapping the axis of the diaphragm guide rod. This arrangement of the first and second inductive sensors perpendicular to each other and their fixed positions spaced far apart prevents the creation of holes in the outer wall of the hydraulic oil chamber at similar locations, effectively ensuring the sealing performance of the hydraulic oil chamber.

[0008] Furthermore, the first inductive sensor and the second inductive sensor have a temperature resistance of 100° C. to 150° C. Thus, the high temperature resistance of the sensors is higher than the maximum temperature of the hydraulic oil chamber, and they can adapt to high temperature environments.

[0009] Furthermore, the diaphragm guide rod is made of carbon steel or alloy steel. Thus, the diaphragm guide rod has high hardness and can trigger the inductive sensor after entering the sensing distance of the inductive sensor. At the same time, it has the characteristics of low cost and simple processing technology.

[0010] A diaphragm pump oil replenishment and discharge control method is described as follows: The diaphragm pump oil replenishment and discharge detection system described above is used to perform real-time position detection on a diaphragm guide rod within a hydraulic oil chamber. During detection, after the diaphragm guide rod reciprocates, the end of the diaphragm guide rod first approaches a first inductive sensor and is within the sensing range of the first inductive sensor, at which point the first inductive sensor's switching value is output to the controller. When the end of the diaphragm guide rod moves within the sensing range of a second inductive sensor, the second inductive sensor outputs the second inductive sensor's switching value to the controller. The controller receives the switching values ​​from the first and second inductive sensors in sequence and, based on the controller's built-in judgment rules, determines the oil level in the hydraulic oil chamber and issues an oil shortage warning or corresponding oil replenishment or discharge control instructions. Thus, the diaphragm guide rod position detection is performed using two spaced-apart inductive sensors. The detection principle is simple and reliable, with strong anti-interference capabilities, effectively avoiding the risk of high-temperature demagnetization, and exhibiting advantages such as a long service life and a stable output signal.

[0011] Furthermore, the diaphragm guide rod output is set to "on" when the end is within the orthographic projection of the first inductive sensor, and "off" otherwise. The diaphragm guide rod output is set to "on" when the end is within the orthographic projection of the second inductive sensor and within its sensing distance, and "off" otherwise. This provides two output options for the diaphragm guide rod output, effectively simplifying the controller's rule-based decision logic.

[0012] Furthermore, when the controller receives the output switch value of the first inductive sensor as "on" and the output switch value of the second inductive sensor as "off", the controller determines that the oil amount in the hydraulic oil chamber is in a normal state; when the controller receives the output switch value of the first inductive sensor as "on" and the output switch value of the second inductive sensor as "on", the controller determines that the hydraulic oil chamber is in an oil-deficient state; when the controller receives the output switch value of the first inductive sensor as "off" or occasionally "on", and the output switch value of the second inductive sensor is "off", the controller determines that the hydraulic oil chamber is in an oil-rich state. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 Schematic diagram of the cross-sectional structure of the diaphragm pump oil replenishment and discharge detection system in the embodiment;

[0014] Figure 2 2 is a diagram showing the positional relationship between the two inductive sensors and the diaphragm guide rod in the embodiment. DETAILED DESCRIPTION

[0015] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings herein can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0016] It should be noted that similar reference numerals and letters denote similar items in the following figures. Therefore, once an item is defined in one figure, it does not require further definition or explanation in subsequent figures. In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the figures, or the orientations or positional relationships in which the inventive product is typically placed when in use. These terms are intended solely to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation, and are therefore not to be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third," etc., are used solely to distinguish descriptions and are not to be construed as indicating or implying relative importance. Furthermore, terms such as "horizontal" and "vertical" do not imply that a component must be absolutely horizontal or overhanging, but rather may be slightly tilted. For example, "horizontal" simply refers to a direction that is more horizontal than "vertical," and does not imply that the structure must be completely horizontal, but rather may be slightly tilted. In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0017] like Figure 1 、 Figure 2As shown, the diaphragm 1 pump oil replenishment and discharge detection system provided in this embodiment includes a diaphragm 1 pump, a diaphragm 1 is provided in the diaphragm 1 pump, the diaphragm 1 divides the inner cavity of the pump body into a hydraulic oil chamber 2 and a medium chamber 3, and a diaphragm guide rod 4 is provided in the middle of the diaphragm 1, one end of which is connected to the diaphragm 1 and the other end extends into the hydraulic oil chamber 2 and is horizontally arranged. The diaphragm guide rod 4 can move axially repeatedly in the hydraulic oil chamber 2; a first inductive sensor 5 and a second inductive sensor 6 are provided in the hydraulic chamber (specifically, in the hydraulic pipe of the diaphragm 1 pump) at intervals, and there is a gap between the first inductive sensor 5 and the second inductive sensor 6 and the outer end surface of the diaphragm guide rod 4; the diaphragm guide rod 4 is a cylindrical guide rod made of metal, which can first move in the reciprocating movement. Then, the diaphragm guide rod 4 approaches the first inductive sensor 5 and the second inductive sensor 6. The first inductive sensor 5 and the second inductive sensor 6 are both long-distance, pressure-resistant inductive sensors with a detection sensing distance of 0.1 to 15 mm. When the diaphragm guide rod 4 approaches the first inductive sensor 5 and the second inductive sensor 6 and is within the sensing distance of the first inductive sensor 5 and the second inductive sensor 6, the first inductive sensor 5 and the second inductive sensor 6 can be triggered in sequence within a certain period of time and output switching values ​​to a controller 7. After receiving the switching values ​​from the first inductive sensor 5 and the second inductive sensor 6, the controller 7 can determine the oil level in the hydraulic oil chamber 2 according to the set judgment rules. In this way, the inductive sensors used have high-temperature resistance and can adapt to the high-temperature environment of the hydraulic oil chamber 2. They also have a large sensing distance and can adapt to the position sensing of the diaphragm guide rod 4 in various operating conditions. At the same time, compared with traditional electromagnetic sensors, electric inductive sensors have simple and reliable detection principles, strong anti-interference capabilities, can effectively avoid the hidden dangers of high-temperature demagnetization, and have the advantages of long service life and stable output signals. The diaphragm guide rod 4 is made of metal, suitable for the magnetic field sensing of the inductive sensor. After the inductive sensor outputs switching information, the controller 7 performs a judgment based on the judgment rules. The judgment logic is highly compatible with existing control systems, eliminating the need for extensive engineering application verification and enabling rapid promotion.

[0018] Specifically, the first and second inductive sensors 5 and 6 used in this application have a temperature resistance of 130°C and a pressure resistance of 30 MPa, and their output signals are switching quantities. These are long-distance, pressure-resistant inductive sensors customized by the applicant. The sensors are manufactured by Tianjin Jinuo Technology Co., Ltd., and the model number of the inductive sensors is XD-M18-0.26-Q12. Based on the principle of electromagnetic induction, the detection system of this embodiment converts measured physical quantities such as displacement, pressure, flow, and vibration into changes in the coil's self-inductance L or mutual inductance M. The measurement circuit then converts these changes in L or M into changes in voltage or current, thereby converting non-electrical quantities into electrical signal outputs and achieving non-electrical quantity measurement. The inductive sensor consists of three main components: an oscillator, a switching circuit, and an amplifying output circuit. The oscillator generates an alternating magnetic field. When a metal target (i.e., the diaphragm guide rod 4 in this embodiment) approaches this magnetic field and reaches the sensing distance, eddy currents are generated within the metal target, causing the oscillator to attenuate and eventually stop oscillating. The changes in the oscillation and stop of the oscillator are processed by the subsequent amplifier circuit and converted into a switching signal, which triggers the drive controller 7, thereby achieving non-contact detection.

[0019] During specific installation, in order to meet the sealing performance requirements of the hydraulic oil chamber 2, a plurality of sealing rings are provided between the first inductive sensor 5 and the hydraulic pipe, and between the second inductive sensor 6 and the hydraulic pipe.

[0020] like Figure 2 As shown, in this embodiment, the first inductive sensor 5 is arranged vertically and is located above the diaphragm guide rod 4; the second inductive sensor 6 is arranged horizontally, and the centerline of the second inductive sensor 6 overlaps with the axis of the diaphragm guide rod 4. In this way, the first inductive sensor 5 and the second inductive sensor 6 are arranged perpendicular to each other and fixed at a distance, which can avoid opening holes in the outer wall of the hydraulic oil chamber 2 at similar positions, thereby effectively ensuring the sealing performance of the hydraulic oil chamber 2. In a specific implementation, the first inductive sensor 5 and the second inductive sensor 6 can also be arranged vertically, with the diaphragm guide rod 4 located below the first inductive sensor 5 and the second inductive sensor 6. The above-mentioned arrangement can also adapt to the determination of the entry of the end of the diaphragm guide rod 4 at shorter and longer distances, but it requires two mounting holes to be opened at the installation location. The two mounting holes are relatively close to each other, which requires a higher sealing process.

[0021] Furthermore, the first inductive sensor 5 and the second inductive sensor 6 have a temperature resistance of 100° C. to 150° C. Thus, the high temperature resistance of the sensors is higher than the maximum temperature of the hydraulic oil chamber 2 and can adapt to high temperature environments.

[0022] Furthermore, the diaphragm guide rod 4 is made of carbon steel or alloy steel. Thus, the diaphragm guide rod 4 has high hardness and can trigger the inductive sensor after entering the sensing distance of the inductive sensor, while having the characteristics of low cost and simple processing technology.

[0023] Specifically, the diaphragm 1 pump oil replenishment and discharge control method using the above-mentioned diaphragm 1 pump oil replenishment and discharge detection system is as follows: the diaphragm 1 pump oil replenishment and discharge detection system as described above is used to perform real-time position detection of the diaphragm guide rod 4 in the hydraulic oil chamber 2. During the detection, after the diaphragm guide rod 4 reciprocates, the end of the diaphragm guide rod 4 first approaches the first inductive sensor 5, and after being within the sensing distance of the first inductive sensor 5, it can output the switching value of the first inductive sensor 5 to the controller 7; when the end of the diaphragm guide rod 4 moves to the sensing distance of the second inductive sensor 6, the second inductive sensor 6 outputs the switching value of the second inductive sensor 6 to the controller 7; the controller 7 receives the switching values ​​of the first inductive sensor 5 and the second inductive sensor 6 in succession, and judges the oil level in the hydraulic oil chamber 2 in combination with the built-in judgment rules of the controller 7, and issues an oil shortage warning or makes corresponding oil replenishment or oil discharge control instructions. In this way, the position of the diaphragm guide rod 4 is detected by two inductive sensors arranged at intervals. The detection principle is simple and reliable, with strong anti-interference ability, and can effectively avoid the hidden danger of high-temperature demagnetization. It has the advantages of long service life and stable output signal.

[0024] Furthermore, when the end of the diaphragm guide rod 4 is within the orthographic projection range of the first inductive sensor 5 (the orthographic projection range is the projection range of the detection end of the inductive sensor), the output switch value is "bright", otherwise the output switch value is "off"; when the end of the diaphragm guide rod 4 is within the orthographic projection range of the second inductive sensor 6 and within the sensing distance of the second inductive sensor 6, the output switch value of the second inductive sensor 6 is "bright", otherwise the output switch value is "off". When the controller 7 receives a "lit" output from the first inductive sensor 5 and a "off" output from the second inductive sensor 6, it determines that the oil level in the hydraulic oil chamber 2 is normal. When the controller 7 receives a "lit" output from the first inductive sensor 5 and a "lit" output from the second inductive sensor 6, it determines that the hydraulic oil chamber 2 is low on oil. When the controller 7 receives a "off" or occasionally "lit" output from the first inductive sensor 5 and a "off" output from the second inductive sensor 6, it determines that the hydraulic oil chamber 2 is high in oil. This allows the diaphragm guide rod 4 to have two outputs, effectively simplifying the controller 7's rule-based decision logic.

[0025] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit the technical solutions. Those skilled in the art should understand that modifications or equivalent replacements of the technical solutions of the present invention that do not depart from the purpose and scope of the technical solutions of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A diaphragm pump oil replenishment and discharge detection system, comprising a diaphragm pump, a diaphragm disposed within the diaphragm pump, the diaphragm dividing the pump body cavity into a hydraulic oil chamber and a medium chamber, a diaphragm guide rod disposed horizontally in the middle of the diaphragm, one end of the diaphragm being connected to the diaphragm and the other end extending into the hydraulic oil chamber, the diaphragm guide rod being capable of axial reciprocal movement within the hydraulic oil chamber; and characterized in that: A first inductive sensor and a second inductive sensor are spaced apart in the hydraulic oil chamber, each of the first and second inductive sensors having a gap with the outer end surface of the diaphragm guide rod. The diaphragm guide rod is a cylindrical metal guide rod capable of successively approaching the first and second inductive sensors during reciprocating movement. The first and second inductive sensors are both long-distance, pressure-resistant inductive sensors with a detection sensing distance of 0.1 to 15 mm. The first inductive sensor is vertically arranged above the diaphragm guide rod; the second inductive sensor is horizontally arranged, with its centerline overlapping the axis of the diaphragm guide rod. When the diaphragm guide rod approaches the first inductive sensor and the second inductive sensor and is within the sensing distance of the first inductive sensor and the second inductive sensor, the first inductive sensor and the second inductive sensor can be triggered successively within a certain period of time and output switching quantities to a controller. After receiving the switching quantities emitted by the first inductive sensor and the second inductive sensor, the controller can judge the oil level in the hydraulic oil chamber according to the set judgment rules.

2. The diaphragm pump oil replenishment and discharge detection system according to claim 1, characterized in that: The first inductive sensor and the second inductive sensor may also be arranged vertically, with the diaphragm guide rod being located below the first inductive sensor and the second inductive sensor.

3. The diaphragm pump oil replenishment and discharge detection system according to claim 1 or 2, characterized in that: The first inductive sensor and the second inductive sensor have a temperature resistance of 100° C. to 150° C.

4. The diaphragm pump oil replenishment and discharge detection system according to claim 3, characterized in that: The diaphragm guide rod is made of carbon steel or alloy steel.

5. A diaphragm pump oil replenishment and discharge control method, characterized in that: The oil replenishment and discharge control method of the diaphragm pump is as follows: the diaphragm pump oil replenishment and discharge detection system as described in any one of claims 1 to 4 is used to perform real-time position detection of the diaphragm guide rod in the hydraulic oil chamber. During the detection, after the diaphragm guide rod reciprocates, the end of the diaphragm guide rod first approaches the first inductive sensor, and after being within the sensing distance of the first inductive sensor, it can output the switching value of the first inductive sensor to the controller; when the end of the diaphragm guide rod moves to the sensing distance of the second inductive sensor, the second inductive sensor outputs the switching value of the second inductive sensor to the controller; the controller receives the switching values ​​of the first inductive sensor and the second inductive sensor in sequence, and judges the oil level of the hydraulic oil chamber in combination with the judgment rules built into the controller, and issues an oil shortage warning or makes corresponding oil replenishment or oil discharge control instructions; when the end of the diaphragm guide rod is within the positive projection range of the first inductive sensor, the output switching value is set to "light", otherwise the output switching value is set to "off"; It is assumed that when the end of the diaphragm guide rod is within the positive projection range of the second inductive sensor and within the sensing distance of the second inductive sensor, the output switch value of the second inductive sensor is "on", otherwise the output switch value is "off"; when the controller receives the output switch value of the first inductive sensor as "on" and the output switch value of the second inductive sensor as "off", the oil amount in the hydraulic oil chamber is normal; when the controller receives the output switch value of the first inductive sensor as "on" and the output switch value of the second inductive sensor as "on", the controller determines that the hydraulic oil chamber is in an oil-deficient state; when the controller receives the output switch value of the first inductive sensor as "off" or occasionally "on", and the output switch value of the second inductive sensor is "off", the controller determines that the hydraulic oil chamber is in an oil-excess state.

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