Performance testing method for a distributed capacitance type continuous liquid level sensor

Abstract

The present invention relates to the technical field of electronic digital data processing, and specifically to a performance testing method for a distributed capacitance type continuous liquid level sensor. The method includes: collecting performance testing environment data of the liquid level sensor, and analyzing to obtain the environmental interference values of each performance testing group; real-time monitoring the testing liquid level height and the output signal of the liquid level sensor of each performance testing group, constructing the liquid level sensor response curve of each performance testing group, and obtaining the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance testing group through processing; comprehensively analyzing to obtain the working performance evaluation index of the liquid level sensor, and evaluating the performance of the liquid level sensor and giving result feedback. By providing a performance testing method for a distributed capacitance type continuous liquid level sensor, the present invention comprehensively analyzes the performance testing data of the liquid level sensor in different environments and different working stages, which is beneficial to ensuring the stability and reliability of the sensor in practical applications.

Description

Technical Field

[0001] The invention relates to the technical field of electronic digital data processing, in particular to a performance testing method for a distributed capacitance continuous liquid level sensor. Background Art

[0002] As the degree of industrial automation increases, the demand for liquid level monitoring also grows. Distributed capacitive sensors can provide non-contact liquid level monitoring solutions, which are suitable for various dangerous or difficult to directly contact environments. In many industrial applications, accurate monitoring of liquid levels is essential to ensure operational safety. For example, in the chemical, energy, and food and beverage industries, improper liquid level control may cause overflows, damage equipment, or cause safety accidents.

[0003] For example, the invention patent with announcement number: CN104462770B discloses a signal reconstruction method that takes into account sensor performance degradation. First, the wavelet function and the number of decomposition layers are selected using the lp norm entropy standard as the cost function; secondly, the wavelet detail coefficients of each layer of the intact signal and the performance-degraded signal are calculated, and the correlation coefficients of the corresponding wavelet detail signals of each layer between the intact signal and the performance-degraded signal are calculated, and the number of layers with correlation coefficients greater than the threshold is located; finally, the correlation coefficients in the wavelet detail coefficients of the layer in the intact signal are replaced with the wavelet detail coefficients of the layer in the performance-degraded signal, and the data is reconstructed using wavelet reconstruction means, thereby completing the signal reconstruction that takes into account sensor performance degradation. This method can effectively utilize the useful information in the performance-degraded signal, so that damage identification and prediction can still be performed according to the existing algorithm when the sensor performance is degraded.

[0004] For example, the invention patent with announcement number: CN102495779B discloses an integrated sensor RFID system and a method for testing the performance of a mixed-mode interface of the system. A logic analysis kit is connected to the mixed-mode interface of the integrated sensor RFID system, including an LA_Probe_E measurement line, an LA6000 logic analyzer, and a host. The interface transmission signal passes through the measurement line, the logic analyzer, and the host, and is decoded by the host computer software to obtain the interface transmission signal characteristics, which are verified with the signal transmission protocol to obtain the plug-and-play performance parameters of the mixed-mode interface. Secondly, electrostatic discharge destructive tests are performed on the host interface and the sensor module interface on the mixed-mode interface bus, respectively, and the plug-and-play validity test method is used to re-perform independent communication and joint communication quality inspections to obtain the hot-swap performance evaluation results of the mixed-mode interface.

[0005] Based on the above solution, it is found that there are still some deficiencies in the current performance testing of liquid level sensors. Specifically, the performance testing of current liquid level sensors mainly focuses on fitting the curve coefficient between the current or voltage of the liquid level sensor to be detected and the liquid level value of the liquid level balance pipe through real-time calculation and display, and preliminarily evaluating the corresponding relationship between the output of the sensor and the liquid level. This testing method depends on a single testing environment and conditions, and it is difficult to comprehensively reflect the performance of the liquid level sensor in actual applications. Summary of the Invention

[0006] In view of the deficiencies of the prior art, the present invention provides a performance testing method for a distributed capacitance continuous liquid level sensor, which can effectively solve the problems involved in the above background technology.

[0007] To achieve the above objectives, the present invention is realized through the following technical solutions: The present invention provides a performance testing method for a distributed capacitance continuous liquid level sensor, including: collecting the performance testing environment data of the liquid level sensor, grouping and testing the liquid level sensor according to the performance testing environment data, and marking them as each performance testing group, obtaining the environmental interference data of each performance testing group, and analyzing to obtain the environmental interference value of each performance testing group.

[0008] Real-time monitor the testing liquid level height and the output signal of the liquid level sensor for each performance testing group, construct the liquid level sensor response curve of each performance testing group, and obtain the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance testing group through processing.

[0009] According to the environmental interference value, the liquid level response accuracy evaluation value, and the liquid level response linearity evaluation value of each performance testing group, comprehensively analyze to obtain the working performance evaluation index of the liquid level sensor, evaluate the performance of the liquid level sensor according to the working performance evaluation index of the liquid level sensor, and obtain the evaluation result and give feedback.

[0010] As a further method, the process of collecting the performance testing environment data of the liquid level sensor, grouping and testing the liquid level sensor according to the performance testing environment data, and marking them as each performance testing group is as follows: collect the performance testing environment data of the liquid level sensor, where the performance testing environment data includes temperature, humidity, and pressure, extract the allowable deviation range of the performance testing environment data from the liquid level sensor database, group the performance testing of the liquid level sensor according to the allowable deviation range of the performance testing environment data, and mark them as each performance testing group.

[0011] As a further method, the environmental interference data of each performance test group is obtained and the environmental interference value of each performance test group is analyzed. The specific analysis process is as follows: According to the environmental interference data of each performance test group, including the electromagnetic signal intensity and vibration intensity of each performance test group, the critical electromagnetic signal intensity and critical vibration intensity are extracted from the liquid level sensor database, and the environmental interference value of each performance test group is obtained through comprehensive analysis.

[0012] As a further method, the test liquid level height and the output signal of the liquid level sensor of each performance test group are monitored in real time, and the liquid level sensor response curve of each performance test group is constructed. The specific process is as follows: A number of time monitoring points are deployed, the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point are collected, and the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point are subjected to linear curve fitting to obtain the liquid level sensor response curve of each performance test group and the relationship function between the test liquid level height and the output signal of the liquid level sensor.

[0013] As a further method, the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance test group are obtained through processing. The specific process is as follows: According to the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point, the liquid level response accuracy evaluation value of each performance test group is obtained through comparative analysis;

[0014] According to the relationship function between the test liquid level height and the output signal of the liquid level sensor of each performance test group, the liquid level response linearity evaluation value of each performance test group is obtained through comprehensive analysis.

[0015] As a further method, the working performance evaluation index of the liquid level sensor is obtained through comprehensive analysis. The specific analysis process is as follows: According to the environmental interference value, the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance test group, the working performance evaluation index of the liquid level sensor is obtained through comprehensive analysis. The working performance evaluation index of the liquid level sensor is used to quantitatively evaluate the working performance of the liquid level sensor.

[0016] As a further method, the performance of the liquid level sensor is evaluated according to the working performance evaluation index of the liquid level sensor, and the evaluation result is obtained and fed back. The specific process is as follows: The working performance evaluation index threshold of the liquid level sensor is extracted from the liquid level sensor database, and the working performance evaluation index of the liquid level sensor is compared with the working performance evaluation index threshold. If the working performance evaluation index of the liquid level sensor is higher than or equal to the working performance evaluation index threshold, the actual working performance of the liquid level sensor is evaluated as qualified; if the working performance evaluation index of the liquid level sensor is lower than the working performance evaluation index threshold, the actual working performance of the liquid level sensor is evaluated as unqualified.

[0017] Feedback the evaluation results to the relevant personnel, and the relevant personnel optimize the performance of the liquid level sensor according to the evaluation of the actual working performance of the liquid level sensor.

[0018] As a further method, the environmental interference value of each performance test group is the quantitative evaluation data obtained through comprehensive analysis of the electromagnetic signal intensity and vibration intensity of each performance test group, which is used to quantitatively evaluate the degree of environmental interference of each performance test group and provide a basis for evaluating the working performance of the liquid level sensor.

[0019] As a further method, the specific analysis process of the liquid level response accuracy evaluation value of each performance test group is as follows: read the output voltage of the liquid level sensor, and based on the linear relationship between the output voltage of the liquid level sensor and the liquid level height, comprehensively analyze to obtain the liquid level response accuracy evaluation value of each performance test group. The specific numerical expression is:

[0020]

[0021] In the formula, represents the liquid level response accuracy evaluation value of the nth performance test group, i represents the number of the time monitoring point, i = 1, 2, 3,..., t, t represents the total number of time monitoring points, P n→i represents the measured liquid level height of the nth performance test group at the ith time monitoring point, H n→i represents the actual liquid level height of the liquid level sensor of the nth performance test group at the ith time monitoring point, and θ represents the liquid level response accuracy evaluation correction factor corresponding to the set liquid level height unit value.

[0022] As a further method, the working performance evaluation index of the liquid level sensor is specifically expressed as:

[0023]

[0024] In the formula, ω represents the working performance evaluation index of the liquid level sensor, represents the liquid level response accuracy evaluation value of the nth performance test group, n represents the number of each performance test group, n = 1, 2, 3,..., m, m represents the total number of performance test groups, X n represents the environmental interference value of the nth performance test group, X 0 represents the reference standard environmental interference value, h represents the test liquid level height variable, h ∈ [h0, h1], h0 represents the starting liquid level height of the test, h1 represents the ending liquid level height of the test, F n (h) represents the relationship function between the test liquid level height of the nth performance test group and the output signal of the liquid level sensor, P(h) represents the linear relationship function between the reference standard liquid level sensor output voltage and the liquid level height, and ρ represents the set liquid level response linearity evaluation correction factor.

[0025] Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects:

[0026] (1) By providing a performance test method for a distributed capacitance continuous liquid level sensor, the present invention comprehensively analyzes the performance test data of the liquid level sensor in different environments and different working stages, helps to timely discover possible problems of the sensor, and by evaluating the adaptability of the sensor in different environments, it helps to determine whether the sensor can maintain stable performance in various environments. At the same time, the reliability of the liquid level sensor in different working stages is verified, which is beneficial to ensuring the stability of the sensor in practical applications.

[0027] (2) By evaluating the environmental interference of the liquid level sensor, the present invention can discover in advance the factors that may cause performance degradation, so as to take preventive measures. It helps to reduce the failure rate of the sensor during use and lower the maintenance cost. By conducting grouped tests on the sensor and analyzing environmental interference, it can ensure that the selected sensor can work stably in a specific environment. It helps to improve the reliability of the entire measurement system, thereby improving the stability and accuracy of the measurement.

[0028] (3) By analyzing the evaluation of the liquid level response accuracy and linearity of the liquid level sensor, the present invention ensures that the sensor provides accurate output signals when the liquid level changes, which is beneficial to improving the measurement accuracy. At the same time, it ensures that the sensor can provide consistent output throughout the entire measurement range, helps to reduce non-linear errors, lower the long-term maintenance cost, and improves the credibility of the measurement results. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will be further described with reference to the accompanying drawings. However, the embodiments in the drawings do not constitute any limitation to the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained according to the following drawings.

[0030] Figure 1 It is a schematic flow chart of the method of the present invention.

[0031] Figure 2 It is a schematic diagram of the functional relationship between the liquid level response accuracy evaluation value of the embodiment of the present invention and the working performance evaluation index of the liquid level sensor. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0033] Reference Figure 1 As shown, the present invention provides a performance test method for a distributed capacitance type continuous liquid level sensor, including: collecting performance test environment data of the liquid level sensor, performing grouped tests on the liquid level sensor according to the performance test environment data, and marking them as each performance test group, obtaining environmental interference data of each performance test group, and analyzing to obtain the environmental interference values of each performance test group.

[0034] Specifically, collecting performance test environment data of the liquid level sensor, performing grouped tests on the liquid level sensor according to the performance test environment data, and marking them as each performance test group. The specific process is: collecting performance test environment data of the liquid level sensor, where the performance test environment data includes temperature, humidity, and pressure, extracting the allowable deviation range of the performance test environment data from the liquid level sensor database, grouping the performance tests of the liquid level sensor according to the allowable deviation range of the performance test environment data, and marking them as each performance test group.

[0035] It should be noted that in this embodiment, through grouped tests, the performance of the liquid level sensor under different environmental conditions is evaluated, as well as those sensors whose performance is greatly affected by the environment. This helps to understand the stability and consistency of the liquid level sensor, as well as the reliability of the liquid level sensor under different environments. Analyzing the relationship between environmental data and sensor performance can reveal which design parameters have a significant impact on sensor performance. Based on these findings, the design of the sensor can be optimized, such as improving sensor materials, adjusting sensor sensitivity, or increasing anti-interference measures. Through testing and analysis, the performance of the sensor under different environmental conditions can be understood, thereby guiding sensor manufacturers to improve the environmental adaptability of their products. For specific applications, the sensor can be customized according to the expected working environment to ensure the best performance. Liquid level sensors working in harsh environments may require higher anti-interference capabilities and stronger mechanical strength. By evaluating the environmental interference of the sensor, factors that may cause performance degradation can be discovered in advance, and preventive measures can be taken. This helps to reduce the failure rate of the sensor during use and lower the maintenance cost. By performing grouped tests and environmental interference analysis on the sensor, it can be ensured that the selected sensor can work stably in a specific environment. This helps to improve the reliability of the entire measurement system and reduce the downtime caused by sensor failures.

[0036] Further, the environmental interference data of each performance test group is obtained and the environmental interference values of each performance test group are analyzed. The specific analysis process is as follows: According to the environmental interference data of each performance test group, including the electromagnetic signal intensity and vibration intensity of each performance test group, the preset critical electromagnetic signal intensity, critical vibration intensity, environmental interference degree influence factor corresponding to the vibration intensity, and environmental interference degree influence factor corresponding to the electromagnetic interference intensity are extracted from the liquid level sensor database, and the environmental interference values of each performance test group are obtained through comprehensive analysis.

[0037] It should be noted that in this embodiment, the electromagnetic signal intensity of each performance test group is monitored by using an electromagnetic field strength meter, and the vibration intensity of each performance test group is measured by using equipment such as a vibration test bench or a seismograph. The electromagnetic signal intensity reflects the energy loss of the liquid level sensor during signal transmission. In practical applications, the liquid level sensor usually needs to transmit signals to a control system far away from the sensor, such as a computer. If the signal intensity is too weak, the signal may be weakened during transmission, thus affecting the accuracy of liquid level measurement. A liquid level sensor with good performance should have sufficient signal intensity to ensure the stability and reliability of the signal during transmission. The vibration intensity refers to the degree of vibration influence on the liquid level sensor during measurement. In an industrial environment, vibration is a common interference factor, which may come from nearby equipment, pipelines, vehicles, etc. If the liquid level sensor is too sensitive to vibration, it may lead to measurement errors and affect the accuracy of liquid level measurement.

[0038] In a specific embodiment, the environmental interference value of each performance test group has the following specific numerical expression:

[0039]

[0040] In the formula, X n represents the environmental interference value of the nth performance test group, n represents the number of each performance test group, n = 1, 2, 3,..., m, m represents the total number of performance test groups, Z n represents the vibration intensity of the nth performance test group, D n represents the electromagnetic interference intensity of the nth performance test group, Z 0 represents the critical vibration intensity, D 0 represents the critical electromagnetic interference intensity, δ1 represents the environmental interference degree influence factor corresponding to the set vibration intensity, and δ2 represents the environmental interference degree influence factor corresponding to the set electromagnetic interference intensity.

[0041] Table 1 Data example of environmental interference values of each performance test group

[0042]

[0043] It should be understood that in this embodiment, the critical vibration intensity is 10m 2 / s, the critical electromagnetic interference intensity is 50 dB, the environmental interference degree influence factor corresponding to the set vibration intensity is fixed at 0.4, and the environmental interference degree influence factor corresponding to the set electromagnetic interference intensity is fixed at 0.6. As shown in Table 1, when the electromagnetic interference intensity is the same, the greater the vibration intensity, the greater the environmental interference value of each performance test group. At the same time, when the vibration intensity is the same, the greater the electromagnetic interference intensity, the greater the environmental interference value of each performance test group. Both show a positive correlation. High-intensity vibration may cause loosening of the internal structure or electrical connections of the sensor, which not only directly affects the measurement accuracy but also may increase the sensitivity of the sensor to external electromagnetic interference. During the testing stage of the sensor, simulating the vibration and electromagnetic interference conditions in the actual working environment can verify the environmental adaptability of the sensor, timely detect potential problems, and perform necessary calibration and optimization to ensure that the product meets the on-site application requirements.

[0044] It should be explained that in this embodiment, this formula describes the calculation method of the environmental interference value in the performance test group, taking into account the vibration intensity, the electromagnetic interference intensity, and the environmental interference degree influence factors corresponding to the vibration intensity and the electromagnetic interference intensity. The formula combines the hyperbolic sine function to simulate the comprehensive influence of the vibration intensity and the electromagnetic interference intensity on the environmental interference value. The value range of the environmental interference degree influence factor corresponding to the set vibration intensity and the environmental interference degree influence factor corresponding to the set electromagnetic interference intensity is [0, 1]. A mapping table is established for the vibration intensity and the electromagnetic interference with the environmental interference degree influence factors corresponding to the vibration intensity and the electromagnetic interference intensity respectively. According to the real-time vibration intensity and electromagnetic interference, the environmental interference degree influence factors corresponding to the real-time vibration intensity and the electromagnetic interference intensity are obtained through the mapping table.

[0045] It should be explained that in this embodiment, by adjusting the environmental interference degree influence factor corresponding to the vibration intensity and the environmental interference degree influence factor corresponding to the electromagnetic interference intensity, the relative sensitivity of the influence of vibration and electromagnetic interference on the device performance under different environments can be evaluated. If the environmental interference degree influence factor corresponding to the vibration intensity is larger, it indicates that the same amplitude change in the vibration intensity has a greater impact on the environmental interference. On the contrary, it indicates that the change in the electromagnetic interference intensity has a greater impact on the environmental interference.

[0046] It should be explained that in this embodiment, the environmental interference value of each performance test group is the quantitative evaluation data obtained through comprehensive analysis of the electromagnetic signal intensity and vibration intensity of each performance test group, which is used to quantitatively evaluate the degree of environmental interference of each performance test group and provide a basis for evaluating the working performance of the liquid level sensor.

[0047] The test liquid level height and the output signal of the liquid level sensor of each performance test group are monitored in real time, and the liquid level sensor response curve of each performance test group is constructed. After processing, the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance test group are obtained.

[0048] Specifically, the process of monitoring the test liquid level height and the output signal of the liquid level sensor of each performance test group in real time and constructing the response curve of the liquid level sensor of each performance test group is as follows: Deploy a number of time monitoring points, collect the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point, and perform linear curve fitting on the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point to obtain the liquid level sensor response curve of each performance test group and the relationship function between the test liquid level height and the output signal of the liquid level sensor.

[0049] In a specific embodiment, the data examples of the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point are as follows in the table.

[0050] Table 2 Data examples of the output signal of the liquid level sensor and the test liquid level height

[0051] Time monitoring point number Output signal of liquid level sensor (v) Measured liquid level height (m) 1 0.45 0.2 2 0.90 0.5 3 1.55 0.8 4 2.10 1.2 5 2.45 1.5

[0052] It should be understood that, as can be seen from Table 2, the expression of the relationship function between the liquid level sensor response curve and the test liquid level height and the output signal of the liquid level sensor of each performance test group is: V = 1.5H + 0.15. Mark this function expression as F n (h), where V represents the output signal voltage of the liquid level sensor and H represents the test liquid level height.

[0053] Furthermore, the process of obtaining the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance test group after processing is as follows: According to the test liquid level height and the output signal of the liquid level sensor of each performance test group at each time monitoring point, extract the liquid level response accuracy evaluation correction factor from the liquid level sensor database, and compare and analyze to obtain the liquid level response accuracy evaluation value of each performance test group;

[0054] According to the relationship function between the test liquid level height and the output signal of the liquid level sensor of each performance test group, extract the liquid level response linearity evaluation correction factor from the liquid level sensor database, and comprehensively analyze to obtain the liquid level response linearity evaluation value of each performance test group.

[0055] In a specific embodiment, the specific analysis process of the liquid level response accuracy evaluation value of each performance test group is: Read the output voltage of the liquid level sensor, and comprehensively analyze to obtain the liquid level response accuracy evaluation value of each performance test group according to the linear relationship between the output voltage of the liquid level sensor and the liquid level height. The specific numerical expression is:

[0056]

[0057] In the formula, represents the liquid level response accuracy evaluation value of the nth performance test group, i represents the number of the time monitoring point, i = 1, 2, 3,..., t, where t represents the total number of time monitoring points, and P n→i represents the measured liquid level height at the ith time monitoring point of the nth performance test group, and H n→i represents the actual liquid level height of the liquid level sensor at the ith time monitoring point of the nth performance test group, and θ represents the liquid level response accuracy evaluation correction factor corresponding to the set unit value of the liquid level height.

[0058] It should be explained that in this embodiment, the linear relationship between the output voltage of the liquid level sensor and the liquid level height is specifically a function. The sensor is installed in a container or the measured liquid environment, the liquid level height is gradually changed, and the output voltage value of the sensor corresponding to each height is recorded. The numerical expression of the linear relationship function between the output voltage of the liquid level sensor and the liquid level height is V = kH + b. According to this function expression, P(h) is obtained: V represents the output voltage of the liquid level sensor of the performance test group, k represents the proportionality coefficient, and b represents the intercept. The proportionality coefficient k determines the sensitivity of the voltage change to the liquid level height change. If the value of k is large, it means that a small liquid level change will cause a significant change in the output voltage; on the contrary, if the value of k is small, it means that a large change in the liquid level is required for the output voltage to change significantly. The unit of the proportionality coefficient is V / m, that is, for every volt change corresponding to every meter change in the liquid level height, and the intercept b represents the output voltage V of the sensor when the liquid level height h makes the output voltage V = 0. This value may be a fixed offset that the system needs to correct, which can help eliminate the deviation caused by the sensor's own characteristics or external environmental factors.

[0059] It should be explained that in this embodiment, the value range of the liquid level response accuracy evaluation correction factor is [0.1, 0.5]. A mapping set between the liquid level response accuracy evaluation value of the performance test group and the liquid level response accuracy evaluation correction factor is established based on the historical data of the liquid level sensor performance test. According to the real-time liquid level response accuracy evaluation value of the performance test group, the real-time liquid level response accuracy evaluation correction factor is obtained through the mapping set. Used for standardized evaluation and error compensation, the correction factor can balance the measurement differences under different test conditions and ensure the comparability of the evaluation results of different test groups or different time periods. The correction factor can also be used to compensate for systematic error sources, such as environmental factors, instrument aging, etc., so that the final evaluation value can better reflect the true performance.

[0060] It should be understood that in this embodiment, the test liquid level height of the performance test group is the preset liquid level height according to the linear relationship equation between the output voltage of the liquid level sensor and the liquid level height. The actual liquid level height of the performance test group is the actual liquid level height measured and displayed when the liquid level sensor conducts the test. The liquid level response accuracy evaluation value of each performance test group is the quantitative evaluation data obtained by analyzing the test liquid level height and the output signal of the liquid level sensor at each time monitoring point, and is used to quantitatively evaluate the response accuracy of the liquid level sensor. The liquid level response linearity evaluation value of each performance test group is the quantitative evaluation data obtained by analyzing the relationship function between the test liquid level height of each performance test group and the output signal of the liquid level sensor, and is used to quantitatively evaluate the response linearity of the liquid level sensor.

[0061] According to the environmental interference value, liquid level response accuracy evaluation value and liquid level response linearity evaluation value of each performance test group, the working performance evaluation index of the liquid level sensor is comprehensively analyzed. According to the working performance evaluation index of the liquid level sensor, the performance of the liquid level sensor is evaluated, and the evaluation result is obtained and fed back.

[0062] Specifically, the comprehensive analysis to obtain the working performance evaluation index of the liquid level sensor, the specific analysis process is: according to the environmental interference value, liquid level response accuracy evaluation value and liquid level response linearity evaluation value of each performance test group, the working performance evaluation index of the liquid level sensor is comprehensively analyzed, and the working performance evaluation index of the liquid level sensor is used to quantitatively evaluate the working performance of the liquid level sensor.

[0063] In a specific embodiment, the specific numerical expression of the working performance evaluation index of the liquid level sensor is:

[0064]

[0065] In the formula, ω represents the working performance evaluation index of the liquid level sensor, represents the liquid level response accuracy evaluation value of the nth performance test group, n represents the number of each performance test group, n = 1, 2, 3,..., m, m represents the total number of performance test groups, X n represents the environmental interference value of the nth performance test group, X 0 represents the reference standard environmental interference value, h represents the test liquid level height variable, h ∈ [h0, h1], h0 represents the starting liquid level height of the test, h1 represents the ending liquid level height of the test, F n (h) represents the relationship function between the test liquid level height of the nth performance test group and the output signal of the liquid level sensor, P(h) represents the linear relationship function between the reference standard liquid level sensor output voltage and the liquid level height, and ρ represents the set liquid level response linearity evaluation correction factor.

[0066] It should be noted that this formula is a comprehensive index for evaluating the working performance of a liquid level sensor, which combines data from multiple performance test groups and the characteristics of the sensor's response to different liquid level heights. Specifically, this evaluation method takes into account the correction of environmental interference and the consistency of the linear relationship between the sensor output and the actual liquid level height. The latter part of the formula integrates the difference between the actual liquid level height of the nth group of tests and the theoretical expected output of the sensor output over the entire test range from the initial liquid level height to the final liquid level height. After integrating this difference and multiplying it by a correction factor, the evaluation value of the liquid level response linearity is further adjusted.

[0067] It should be noted that in this embodiment, the value range of the correction factor for evaluating the liquid level response linearity is [0, 1]. A mapping set between the evaluation value of the liquid level response linearity of the performance test group and the correction factor for evaluating the liquid level response linearity is established based on the historical data of the performance test of the liquid level sensor. According to the real-time evaluation value of the liquid level response linearity of the performance test group, the real-time correction factor for evaluating the liquid level response linearity is obtained through the mapping set. When the correction factor for evaluating the liquid level response linearity approaches 1, it indicates that more importance is attached to the influence of the evaluation value of the liquid level response linearity on the evaluation of the working performance of the liquid level sensor; when the correction factor for evaluating the liquid level response linearity approaches 0, more reliance is placed on the evaluation value of the liquid level response linearity of the performance test group and the influence of environmental factors on the evaluation of the working performance of the liquid level sensor.

[0068] It should be noted that as Figure 2 shown, curve a represents the relationship between the evaluation value of the liquid level response accuracy of the performance test group and the working performance evaluation index of the liquid level sensor when the evaluation value of the liquid level response linearity of the performance test group is 1. Curve b represents the relationship between the evaluation value of the liquid level response accuracy of the performance test group and the working performance evaluation index of the liquid level sensor when the evaluation value of the liquid level response linearity of the performance test group is 1.25. Curve c represents the relationship between the evaluation value of the liquid level response accuracy of the performance test group and the working performance evaluation index of the liquid level sensor when the evaluation value of the liquid level response linearity of the performance test group is 1.5. It can be Figure 2 seen that the larger the evaluation value of the liquid level response linearity of the performance test group, the larger the working performance evaluation index of the liquid level sensor. At the same time, the larger the evaluation value of the liquid level response accuracy of the performance test group, the larger the working performance evaluation index of the liquid level sensor. Both show a positive correlation.

[0069] It should be understood that the performance evaluation of liquid level sensors is crucial to ensure their reliable operation in multiple fields such as industrial automation, environmental monitoring, and chemical production. Among them, the liquid level response linearity and accuracy are two important indicators to measure the performance of sensors, and they have significant benefits for evaluating their performance: The liquid level response linearity refers to the degree of linear relationship between the output signal of the sensor and the actual liquid level change. An ideal sensor should have a perfect proportional relationship, that is, a linear relationship, between its output signal and the liquid level when the liquid level changes. A sensor with high linearity makes the calibration curve close to a straight line, simplifies the calibration process, and reduces the calibration cost and time. A sensor with good linearity can provide a consistent error distribution throughout the full scale range, reducing the non-linear error and enhancing the credibility of the measurement results. For a control system, a linear output signal is easier to process and interpret, which helps to achieve more accurate process control and automated decision-making. Because a sensor with high linearity exhibits more stable behavior during use, reducing false alarms or troubleshooting caused by non-linear errors, thus reducing the long-term maintenance cost. And accuracy refers to the degree of closeness between the measured value of the sensor and the true value, usually expressed as a percentage of the absolute error or relative error. High accuracy means that the measurement result is closer to the true value, which is crucial for industrial applications that require high-precision control, such as chemical reaction batching and pharmaceutical manufacturing. Accurate liquid level measurement can help optimize inventory management and reduce material waste. Especially in continuous production processes, precise control of raw material consumption can significantly improve production efficiency. In some applications, accurate liquid level measurement is crucial for preventing safety accidents such as spills and idling, ensuring production safety. In summary, the liquid level response linearity and accuracy are key parameters for evaluating the performance of liquid level sensors. They are directly related to the accuracy of measurement and the overall performance of the system, and are of great significance for improving production efficiency, ensuring product quality, ensuring safe operation, and reducing costs, etc.

[0070] Furthermore, the performance of the liquid level sensor is evaluated according to the working performance evaluation indicators of the liquid level sensor, and the evaluation result is obtained and fed back. The specific process is as follows: Extract the threshold values of the working performance evaluation indicators of the liquid level sensor from the liquid level sensor database, compare the working performance evaluation indicators of the liquid level sensor with the threshold values of the working performance evaluation indicators. If the working performance evaluation indicators of the liquid level sensor are higher than or equal to the threshold values of the working performance evaluation indicators, the actual working performance of the liquid level sensor is evaluated as qualified; if the working performance evaluation indicators of the liquid level sensor are lower than the threshold values of the working performance evaluation indicators, the actual working performance of the liquid level sensor is evaluated as unqualified.

[0071] The evaluation result is fed back to the relevant personnel, and the relevant personnel optimize the performance of the liquid level sensor according to the actual working performance evaluation of the liquid level sensor.

[0072] Specifically, the liquid level sensor database is a system that centrally stores and manages information related to liquid level sensors. Its establishment and maintenance are of great significance and play important roles in multiple fields, which are specifically reflected in the following aspects: The database gathers information on liquid level sensors of different types, brands, and performance parameters, providing users with a unified data access platform, facilitating engineers, researchers, purchasers, etc. to obtain comprehensive and accurate product information, and promoting the sharing of knowledge and technology. During the design or procurement stage, engineers can quickly screen out eligible liquid level sensors from the database according to specific application requirements, compare the performance indicators of different products (such as accuracy, response time, operating temperature range, compatibility, etc.), and thus make more reasonable choices. The historical data and performance indicators in the database can be used as a benchmark for evaluating the working status of sensors. By comparing with the actual operation data, the changing trend of sensor performance can be analyzed, and a decline in performance can be detected in a timely manner, providing a basis for the maintenance, calibration, and even replacement of sensors, and continuously optimizing the system performance. The database can provide users with detailed technical documents, operation guides, troubleshooting methods, and other materials, helping users better understand and use liquid level sensors, and improving the quality and efficiency of after-sales service. By analyzing data such as the sales situation, application fields, and user feedback of sensor models in the database, it can help manufacturers understand changes in market demand, guide the R & D direction of new products, and predict industry development trends. For procurement and supply chain managers, the database can provide information such as inventory status, price fluctuations, and supplier evaluations, supporting more effective inventory control and supplier management, reducing costs, and improving the flexibility and response speed of the supply chain. In this embodiment, the liquid level sensor database is used to store relevant data for the performance testing of liquid level sensors, specifically including the critical electromagnetic signal intensity, critical vibration intensity, environmental interference degree influence factor corresponding to the vibration intensity, environmental interference degree influence factor corresponding to the electromagnetic interference intensity, liquid level response accuracy evaluation correction factor, liquid level response linearity evaluation correction factor, reference standard environmental interference value, and the threshold of the working performance evaluation index of the liquid level sensor.

[0073] In a specific embodiment, the evaluation results can be fed back to relevant personnel by designing an automated reporting system. When the interactive quality evaluation is completed and compared with the threshold, the system automatically generates a detailed evaluation report, including scores for each indicator, total score, whether it is qualified, etc., and automatically sends it to the responsible team and management personnel via email, text message, or the internal messaging system. At the actual operation level, obvious warning labels or color coding can be attached to unqualified liquid level sensors to prompt the staff on the production line that these devices need to be repaired or replaced, avoiding misuse.

[0074] It should be noted that by comparing the working performance evaluation indicators of the liquid level sensor with the threshold values of the working performance evaluation indicators, sensors with working performance lower than the expected threshold can be identified in a timely manner, avoiding system errors or failures caused by poor sensor performance, thereby improving the working reliability of the entire monitoring or control system. The comparison of performance indicators helps to verify whether the sensor can meet the measurement accuracy requirements of specific applications. Only when the performance indicators of the sensor, such as accuracy, linearity, response time, etc., meet or exceed the threshold values, can accurate and reliable measurement data be ensured. Regular comparison can be used as part of preventive maintenance to detect potential performance degradation in advance, avoid sudden failures, reduce unplanned downtime, extend the service life of equipment, and reduce maintenance costs. Based on the comparison results, targeted resource allocation can be carried out. For example, sensors with poor performance can be replaced preferentially, or less maintenance inspections can be carried out on sensors with excellent performance, thereby improving maintenance efficiency and resource utilization efficiency. In some highly regulated industries, such as chemical industry, pharmaceutical industry, food processing, etc., the performance of sensors must meet specific safety and quality standards. Comparing the working performance with the threshold values helps to ensure compliance and avoid legal risks and safety hazards caused by non-compliant operations. Through regular evaluation and feedback, sensor performance data can be collected, the reasons for performance degradation can be analyzed, providing a basis for sensor selection, design improvement, or supplier evaluation, and promoting technological progress and product optimization. For customers or regulatory agencies, presenting the comparison results of sensor performance with standard threshold values can increase trust, prove that the performance of the system or product meets the requirements, and improve market competitiveness. In summary, comparing the working performance indicators of the liquid level sensor with the indicator threshold values is a basic step to ensure the effective operation of the sensor, improve system performance, ensure safety and compliance, and optimize management decisions, which is of great significance for improving the overall operation efficiency and product quality.

[0075] The above content is only an example and explanation of the structure of the present invention. Those skilled in the art of this technology can make various modifications or supplements to the described specific embodiments or use similar methods for substitution, as long as they do not deviate from the structure of the invention or exceed the scope defined by this claim book, they should all fall within the protection scope of the present invention.

Claims

1. A performance testing method for a distributed capacitance type continuous liquid level sensor, characterized in that, Including: Collect the performance test environment data of the liquid level sensor, conduct grouped tests on the liquid level sensor according to the performance test environment data, and label them as each performance test group. Obtain the environmental interference data of each performance test group, and analyze to obtain the environmental interference values of each performance test group. Real-time monitor the test liquid level height and the output signal of the liquid level sensor for each performance test group, construct the liquid level sensor response curve of each performance test group, and obtain the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance test group after processing. According to the environmental interference values, the liquid level response accuracy evaluation values, and the liquid level response linearity evaluation values of each performance test group, comprehensively analyze to obtain the working performance evaluation index of the liquid level sensor. Evaluate the performance of the liquid level sensor according to the working performance evaluation index of the liquid level sensor, obtain the evaluation result and give feedback. The process of obtaining the liquid level response accuracy evaluation value and the liquid level response linearity evaluation value of each performance test group after processing is as follows: According to the test liquid level height and the output signal of the liquid level sensor at each time monitoring point of each performance test group, compare and analyze to obtain the liquid level response accuracy evaluation value of each performance test group. According to the relationship function between the test liquid level height and the output signal of the liquid level sensor of each performance test group, comprehensively analyze to obtain the liquid level response linearity evaluation value of each performance test group. The process of comprehensively analyzing to obtain the working performance evaluation index of the liquid level sensor is as follows: According to the environmental interference values, the liquid level response accuracy evaluation values, and the liquid level response linearity evaluation values of each performance test group, comprehensively analyze to obtain the working performance evaluation index of the liquid level sensor. The working performance evaluation index of the liquid level sensor is used to quantitatively evaluate the working performance of the liquid level sensor.

2. The performance testing method of a distributed capacitance type continuous liquid level sensor according to claim 1, wherein: The process of collecting the performance test environment data of the liquid level sensor, conducting grouped tests on the liquid level sensor according to the performance test environment data, and labeling them as each performance test group is as follows: Collect the performance test environment data of the liquid level sensor, where the performance test environment data includes temperature, humidity, and pressure. Extract the allowable deviation range of the performance test environment data from the liquid level sensor database, and group the performance test of the liquid level sensor according to the allowable deviation range of the performance test environment data, and label them as each performance test group.

3. The performance testing method of a distributed capacitance type continuous liquid level sensor according to claim 1, wherein: The process of obtaining the environmental interference data of each performance test group and analyzing to obtain the environmental interference values of each performance test group is as follows: According to the environmental interference data of each performance test group, including the electromagnetic signal intensity and vibration intensity of each performance test group, extract the critical electromagnetic signal intensity and critical vibration intensity from the liquid level sensor database, and comprehensively analyze to obtain the environmental interference values of each performance test group.

4. The performance testing method of a distributed capacitance type continuous liquid level sensor according to claim 1, characterized in that: The process of real-time monitoring the test liquid level height and the output signal of the liquid level sensor for each performance test group and constructing the liquid level sensor response curve of each performance test group is as follows: Deploy several time monitoring points, collect the measured liquid level heights and the output signals of the liquid level sensors of each performance test group at each time monitoring point, perform linear curve fitting on the measured liquid level heights and the output signals of the liquid level sensors of each performance test group at each time monitoring point, and obtain the liquid level sensor response curves of each performance test group and the relationship function between the measured liquid level height and the output signal of the liquid level sensor.

5. The performance testing method of a distributed capacitance type continuous liquid level sensor according to claim 1, characterized in that: Evaluate the performance of the liquid level sensor according to the working performance evaluation index of the liquid level sensor, obtain the evaluation result and give feedback. The specific process is as follows: Extract the threshold of the working performance evaluation index of the liquid level sensor from the liquid level sensor database, compare the working performance evaluation index of the liquid level sensor with the threshold of the working performance evaluation index. If the working performance evaluation index of the liquid level sensor is higher than or equal to the threshold of the working performance evaluation index, evaluate the actual working performance of the liquid level sensor as qualified; if the working performance evaluation index of the liquid level sensor is lower than the threshold of the working performance evaluation index, evaluate the actual working performance of the liquid level sensor as unqualified. Feed back the evaluation result to the relevant personnel, and the relevant personnel optimize the performance of the liquid level sensor according to the actual working performance evaluation of the liquid level sensor.

6. The performance testing method of a distributed capacitance type continuous liquid level sensor according to claim 3, characterized in that: The environmental interference value of each performance test group is the quantitative evaluation data obtained by comprehensively analyzing the electromagnetic signal intensity and vibration intensity of each performance test group, and is used to quantitatively evaluate the degree of environmental interference of each performance test group, providing a basis for evaluating the working performance of the liquid level sensor.

7. A performance testing method for a distributed capacitance type continuous liquid level sensor according to claim 1, characterized in that: The specific analysis process of the liquid level response accuracy evaluation value of each performance test group is as follows: Read the output voltage signal of the liquid level sensor, and obtain the measured liquid level height of each time monitoring point according to the linear relationship between the output voltage signal of the liquid level sensor and the liquid level height. The liquid level response accuracy evaluation value of each performance test group is obtained through comprehensive analysis. The specific numerical expression is: In the formula, represents the liquid level response accuracy evaluation value of the nth performance test group, i represents the number of the time monitoring point, i = 1, 2, 3,..., t, where t represents the total number of time monitoring points, and P n→i represents the measured liquid level height at the ith time monitoring point of the nth performance test group, and H n→i represents the actual liquid level height of the liquid level sensor at the ith time monitoring point of the nth performance test group, and θ represents the correction factor for evaluating the liquid level response accuracy corresponding to the set unit value of the liquid level height.

8. The performance testing method of a distributed capacitance type continuous liquid level sensor according to claim 1, characterized in that: The specific numerical expression of the working performance evaluation index of the liquid level sensor is: Where, ω represents the working performance evaluation index of the liquid level sensor, represents the liquid level response accuracy evaluation value of the nth performance test group, n represents the number of each performance test group, n = 1, 2, 3,..., m, m represents the total number of performance test groups, X n represents the environmental interference value of the nth performance test group, X 0 represents the reference standard environmental interference value, h represents the test liquid level height variable, h ∈ [h0, h1], h0 represents the starting liquid level height of the test, h1 represents the ending liquid level height of the test, F n (h) represents the relationship function between the test liquid level height of the nth performance test group and the output signal of the liquid level sensor, P(h) represents the linear relationship function between the output voltage of the reference standard liquid level sensor and the liquid level height, ρ represents the set correction factor for evaluating the linearity of the liquid level response.

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