A multi-channel programmable explosion-proof digital display pressure sensor

Abstract

This invention discloses a multi-channel programmable explosion-proof digital display pressure sensor, comprising a housing and within the housing a human-machine interface module for viewing current measured values ​​and modifying configuration information to complete human-machine interaction, an acquisition module for acquiring medium pressure signals, an auxiliary module, an analog channel for realizing analog signal output, a digital channel for realizing digital signal output, a communication channel for realizing IO-Link bus communication, an M12-5 waterproof connector for signal output within the analog, digital, and communication channels and for main power input, a core controller for controlling, coordinating, and processing data for all electrical components of the sensor, and a power isolation step-down circuit. The measurement method of this invention can be arbitrarily configured as absolute pressure mode or relative pressure mode, and the measurement medium can be any non-corrosive liquid or gas medium, making its application range wider.

Description

Technical Field

[0001] This invention relates to the field of pressure sensor technology, and more specifically to a multi-channel programmable explosion-proof digital display pressure sensor. Background Technology

[0002] A pressure sensor is a device that senses pressure signals and converts them into usable electrical signals according to a certain rule. Pressure sensors are among the most commonly used sensors in process control, and are widely applied in various automated control environments, including water conservancy and hydropower, railway transportation, intelligent buildings, production automation, aerospace, military, petrochemicals, oil wells, power, shipbuilding, machine tools, pipelines, and many other industries.

[0003] Currently, mainstream digital pressure sensors on the market can be categorized by output type into NPN open-drain output type, PNP open-drain output type, 0.00-10.00V analog voltage output type, 0.00-20.00mA analog current output type, and 4.00-20.00mA analog current output type. Considering the increasingly large and complex process control systems of today, a single sensor within the system typically has two or more "host computers" with different input signal types. However, for mainstream digital pressure sensors currently on the market, if applied to such systems, an additional signal transmitter module is required as an "intermediate device" to meet the process control system's requirements for sensor signal interfaces. This additional "intermediate device" increases the manufacturing cost of the process control system and significantly reduces its stability.

[0004] Some sensor manufacturers have designed and produced digital pressure sensors with composite signal outputs to address the aforementioned issues. However, some highly customized process control systems still require digital pressure sensors with functionalities such as digital signal action logic adjustment, analog signal type switching (current / voltage), analog signal-pressure signal mapping adjustment, and extreme data recording. In some extremely complex and harsh environments, process control systems also require digital pressure sensors with high electromagnetic compatibility, vibration performance, salt spray corrosion resistance, and temperature shock resistance. Some process control systems with high precision requirements also require digital pressure sensors with high repeatability, temperature drift, and measurement accuracy. In some process control systems within confined spaces, where operators cannot easily manipulate the digital pressure sensor to modify configuration information, the sensor is also required to have the function of remotely configuring operating parameters.

[0005] Furthermore, in process control systems operating in hazardous gas environments, the selection of pressure sensors is further limited because only explosion-proof pressure sensors can be used. Currently, there are many mature pressure sensor products available in both domestic and international markets, but they are often limited in function and require additional "intermediate equipment" to meet the needs of the application scenario. This also increases the manufacturing cost and stability of the process control system. More importantly, these additional connections pose additional challenges to the safe operation of the process control system in hazardous gas environments. Summary of the Invention

[0006] The purpose of this invention is to provide a multi-channel programmable explosion-proof digital display pressure sensor to solve the above-mentioned problems and overcome the shortcomings of the prior art, as detailed below.

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

[0008] This invention provides a multi-channel programmable explosion-proof digital display pressure sensor, comprising a housing and an internal human-machine interaction module for viewing current measured values ​​and modifying configuration information to complete human-machine interaction, an acquisition module for acquiring medium pressure signals, an auxiliary module, an analog channel for realizing analog signal output, a digital channel for realizing digital signal output, a communication channel for realizing IO-Link bus communication, an M12-5 waterproof connector for signal output in the analog channel, digital channel and communication channel and for main power input, a core controller for controlling, coordinating and data processing functions of all parts of the device, and a power isolation step-down circuit.

[0009] Among them, the human-computer interaction module, the data acquisition module, the auxiliary module, the analog channel, the digital channel, and the communication channel are all connected to the core controller.

[0010] The power isolation step-down circuit is connected to the M12-5 waterproof connector to step down the input main power supply to power all parts of the circuit.

[0011] The outer shell has a micro-hole, an explosion-proof vent valve is installed inside the micro-hole, and a waterproof and breathable membrane is installed at the port of the micro-hole.

[0012] Preferably, the human-computer interaction module includes an OLED display screen for displaying real-time pressure values ​​and configuration information, and a capacitive touch panel for real-time acquisition of its touch status. The OLED display screen and the capacitive touch panel are respectively connected to the core controller.

[0013] Preferably, the acquisition module includes an analog signal conditioning circuit for conditioning the weak piezoelectric signal and transmitting the obtained pressure signal to the core control unit for sampling. The analog signal conditioning circuit is connected to a piezoelectric pressure transmitter for directly converting the pressure signal of the medium in the target pipeline into a weak piezoelectric signal and transmitting it thereto. The analog signal conditioning circuit and the core controller are connected to each other.

[0014] Preferably, the auxiliary module includes an F-RAM memory for storing and reading configuration information and a precision voltage reference source for providing a voltage reference source to the core controller. The F-RAM memory and the core controller are connected to each other. The precision voltage reference source and the core controller are also connected to each other.

[0015] Preferably, the analog channel includes a precision current loop driver for outputting analog current signals, a precision voltage driver for outputting analog voltage signals, and an isolation combiner for combining the analog precision current loop driver and the precision voltage driver and outputting them externally through an M12-5 pin waterproof connector. The precision current loop driver and the precision voltage driver are respectively connected to the core controller, and the isolation combiner is respectively connected to the precision current loop driver, the precision voltage driver, and the M12-5 pin waterproof connector.

[0016] Preferably, the digital channel includes a high-side switch for outputting PNP open-drain type digital signals, a low-side switch for outputting NPN open-drain type digital signals, and an isolation combiner II for combining the high-side switch and the low-side switch and outputting them externally through an M12-5 core waterproof connector. The high-side switch and the low-side switch are respectively connected to the core controller, and the isolation combiner II is respectively connected to the high-side switch, the low-side switch, and the M12-5 core waterproof connector.

[0017] Preferably, the communication channel includes an IO-Link interface circuit, which is connected to the core controller and to an M12-5 waterproof connector via an EMC network.

[0018] Preferably, the thickness of the outer shell is 5.0 mm, and the outer shell is made of 440C ultra-hard martensitic stainless steel.

[0019] The beneficial effects are:

[0020] 1. The measurement method of the present invention can be arbitrarily configured as absolute pressure mode and relative pressure mode, and the measurement medium can be any non-corrosive liquid and gas medium, making its application range wider;

[0021] 2. The measured values ​​can be viewed on-site through the human-machine interaction module or remotely through the IO-Link bus. All configuration information can be viewed and adjusted on-site (programmed) through the human-machine interaction module or remotely viewed and modified through the IO-Link bus, making it easier to operate.

[0022] 3. It has analog channels, digital channels and communication channels. The three channels can be enabled, disabled at the same time or enabled individually, which makes it more flexible and versatile and can be applied to various complex process control system environments.

[0023] 4. Its analog channel signal output type can be configured as disabled, current signal type and voltage signal type, and the linear mapping relationship between the output signal and the measured value can be arbitrarily configured, enabling it to upload analog signals to most process control data acquisition devices, thus improving its applicability;

[0024] 5. Its digital channel signal output type can be configured as disabled, NPN open-drain, PNP open-drain and push-pull type, the action logic can be configured as normally open, normally closed, normally low or normally high, and the action mode can be configured as single point, window and hysteresis, so that it can drive most relays, valves or acquisition devices in process control systems, etc., and has better applicability.

[0025] 6. The communication channel's operating states include communication state and digital state, with communication state always having the highest priority. In communication state, the IO-Link master station can access the invention in real time via the IO-Link bus, allowing for remote real-time viewing of measured values, configuration information, or adjustment of configuration information, facilitating configuration information adjustment in process control environments with limited space. In digital state, its operating characteristics are identical to those of the digital channel signal, serving as an extension to facilitate the simultaneous operation of two relays, valves, or acquisition devices with different digital signal output types, action logic, and action methods in the process control field.

[0026] 7. It has an over-limit measurement event recording function, and the over-limit threshold can be adjusted, which facilitates the recording of abnormal state events of the measured medium pressure, thereby improving the reliability and safety of the process control system.

[0027] 8. It adopts a sealed shell, an isolated touch operation method, and an M12-5 waterproof connector design, achieving an IP69K protection rating;

[0028] 9. It has good explosion-proof performance and can be used in hazardous gas explosion areas;

[0029] 10. It has a high EMC performance level and is suitable for electromagnetic compatibility sensitive environments and harsh electromagnetic compatibility environments. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a circuit block diagram of the present invention;

[0032] Figure 2 This is a front view of the upper surface of the outer casing of the present invention;

[0033] Figure 3 This is a cross-sectional view of the upper surface of the outer casing of the present invention;

[0034] Figure 4 This is a topology diagram of the process control system of the present invention.

[0035] The reference numerals in the attached diagram are explained as follows: 1. OLED display screen; 2. Capacitive touch panel; 3. Piezoelectric pressure transmitter; 4. Analog signal conditioning circuit; 5. F-RAM memory; 6. Precision voltage reference source; 7. Core controller; 8. Precision current loop driver; 9. Precision voltage driver; 10. High-side switch; 11. Low-side switch; 12. IO-Link interface circuit; 13. Isolation combiner one; 14. Isolation combiner two; 15. EMC network; 16. M12-5 core waterproof connector; 17. Miniature through-hole; 18. Waterproof and breathable membrane; 19. Housing; 20. Explosion-proof vent valve. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0037] See Figures 1-4 As shown, the present invention provides a multi-channel programmable explosion-proof digital display pressure sensor, which has two measurement modes: absolute pressure and relative pressure, and is associated with measurement mode configuration information. Its range is 0.00-600.00 bar; it has an over-limit measurement event recording function and is associated with over-limit measurement threshold configuration information.

[0038] A multi-channel programmable explosion-proof digital display pressure sensor includes a human-machine interface module consisting of an OLED display screen 1 and a capacitive touch panel 2; an acquisition module consisting of a piezoelectric pressure transmitter 3 and an analog signal conditioning circuit 4; an auxiliary module consisting of an F-RAM memory 5 and a precision voltage reference source 6; an analog channel consisting of a precision current loop driver 8, a precision voltage driver 9, and an isolation combiner 13; a digital channel consisting of a high-side switch 10, a low-side switch 11, and an isolation combiner 14; a communication channel consisting of an IO-Link interface circuit 12 and an EMC network 15; an M12-5 core waterproof connector 16; a core controller 7; and a power isolation step-down circuit. The core controller 7 is used for the control, coordination, and data processing of all electrical components of the sensor. The isolation combiner 13 provides electrical isolation and power limiting for the output analog signal, and the isolation combiner 14 provides electrical isolation and power limiting for the output digital signal.

[0039] The human-computer interaction module is used to complete human-computer interaction, such as viewing the current measurement value and modifying configuration information. Among them, the OLED display screen 1 is connected to the core controller 7 and driven by the core controller 7 to display real-time pressure values ​​and configuration information; the capacitive touch panel 2 is connected to the core controller 7 and its touch status is collected by the core controller 7 in real time.

[0040] The acquisition module is used for acquiring medium pressure signals. Specifically, the piezoelectric pressure transmitter 3 is connected to the analog signal conditioning circuit 4, which is used to directly convert the absolute pressure signal of the medium in the target pipeline into a weak piezoelectric signal and transmit it to the analog signal conditioning circuit 4. The analog signal conditioning circuit 4 is connected to the core controller 7, which is used to condition the weak piezoelectric signal and transmit the obtained pressure signal to the core controller 7 for sampling.

[0041] The auxiliary module is used to implement auxiliary functions, wherein: the F-RAM memory 5 is connected to and driven by the core controller 7, and is used to store and read configuration information, etc.; the precision voltage reference source 6 is connected to the core controller 7, and is used to provide a voltage reference source to the core controller 7.

[0042] The analog channel is used to output analog signals. Specifically: a precision current loop driver 8 is connected to and driven by the core controller 7 to output analog current signals; a precision voltage driver 9 is connected to and driven by the core controller 7 to output analog voltage signals; an isolation combiner 13 is connected to the precision current loop driver 8, the precision voltage driver 9, and the M12-5 waterproof connector 16, respectively, to combine the aforementioned analog precision current loop driver 8 and precision voltage driver 9 and output them externally through the M12-5 waterproof connector 16; the signal output type of the analog channel can be configured as disabled, current signal type, and voltage signal type, associated with the analog channel output type configuration information; the current signal type output range of the analog channel is 0.00-20.00mA, and the voltage signal type output range is 0.00-10.00V; the linear mapping relationship between the output signal and the measured value of the analog channel can be arbitrarily adjusted within the range and output range, associated with the analog channel output mapping relationship configuration information.

[0043] The digital channel is used to output digital signals. Specifically: the high-side switch 10 is connected to and driven by the core controller 7, and is used to output PNP open-drain type digital signals; the low-side switch 11 is connected to and driven by the core controller 7, and is used to output NPN open-drain type digital signals, or in conjunction with the high-side switch 10, to output push-pull type digital signals; the isolation combiner 14 is connected to the high-side switch 10, the low-side switch 11, and the M12-5-pin waterproof connector 16, respectively, to combine the high-side switch 10 and the low-side switch 11 and output them externally through the M12-5-pin waterproof connector 16; the signal output type of the digital channel can be configured as disabled, NPN open-drain, PNP open-drain, and push-pull, associated with the digital channel output type configuration information; its operating logic can be configured as normally open and normally closed, associated with the digital channel operating type configuration information; the operating mode of the digital channel can be configured as single-point, window, and hysteresis, associated with the digital channel operating mode configuration information; the operating threshold of the digital channel can be arbitrarily configured within the range, associated with the digital channel operating threshold configuration information.

[0044] The communication channel is used to realize IO-Link bus communication, wherein: IO-Link interface circuit 12 is connected to and driven by core controller 7, and is used to realize bus communication with external IO-Link devices; EMC network 15 is connected to IO-Link interface circuit 12 and M12-5 waterproof connector 16, and is used to isolate and filter EMC interference coupled into the external IO-Link devices through the IO-Link bus and output it to the outside through M12-5 waterproof connector 16;

[0045] The operating states of a communication channel include a communication state and a digital state; the communication state has the highest priority; the operating characteristics of the communication channel in its digital state are the same as those in its digital state. Analog channels, digital channels, and communication channels can be enabled simultaneously, disabled simultaneously, or enabled individually.

[0046] In addition to signal output in analog, digital, and communication channels, the M12-5-pin waterproof connector 16 is also used for main power input and is connected to a power isolation step-down circuit to step down the input main power supply for powering all circuits in the entire device.

[0047] All configuration information can be viewed, adjusted, and programmed remotely via the human-machine interface module or the IO-Link bus;

[0048] The outer casing 19 is made of 5.0mm thick 440C ultra-hard martensitic stainless steel to achieve a static pressure resistance rating of 1.5MPa.

[0049] The upper surface of the housing 19 is pre-designed with micro-through holes 17, into which explosion-proof ventilation valves 20 are embedded. An IP69K waterproof and breathable membrane 18 is fixed to the outer wall side surface of the micro-through holes 17, ensuring that the integrated micro pressure sensor inside the core controller 7 can effectively and reliably connect to the atmosphere while also having an IP69K dustproof and waterproof rating, and ensuring that the explosion-proof performance is not affected.

[0050] The power isolation step-down circuit provides electrical isolation and power limitation for the input DC power supply, thereby enabling the transmission, interaction, isolation, and power limitation of signals and power between the safe side inside the explosion-proof enclosure and the dangerous side outside the enclosure.

[0051] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A multi-channel programmable explosion-proof digital display pressure sensor, characterized in that: The system includes a housing and an internal human-machine interface module for viewing current measurement values ​​and modifying configuration information; a data acquisition module for acquiring medium pressure signals; an auxiliary module; an analog channel for outputting analog signals; a digital channel for outputting digital signals; a communication channel for IO-Link bus communication; an M12-5 waterproof connector for signal output in the analog, digital, and communication channels and for main power input; a core controller for controlling, coordinating, and processing data for all electrical components of the machine; and a power isolation step-down circuit. Among them, the human-computer interaction module, the data acquisition module, the auxiliary module, the analog channel, the digital channel, and the communication channel are all connected to the core controller. The outer shell has a thickness of 5.0 mm and is made of 440C ultra-hard martensitic stainless steel. The power isolation step-down circuit is connected to the M12-5 waterproof connector to step down the input main power supply to power all circuits of the whole machine. The outer shell has a micro-hole, an explosion-proof vent valve is installed inside the micro-hole, and a waterproof and breathable membrane is installed at the port of the micro-hole. The human-computer interaction module includes an OLED display screen for displaying real-time pressure values ​​and configuration information and a capacitive touch panel for real-time acquisition of its touch status. The OLED display screen and the capacitive touch panel are respectively connected to the core controller. The acquisition module includes an analog signal conditioning circuit for conditioning weak piezoelectric signals and transmitting the resulting pressure signals to the core control unit for sampling. The analog signal conditioning circuit is connected to a piezoelectric pressure transmitter for directly converting the pressure signal of the medium in the target pipeline into a weak piezoelectric signal and transmitting it thereto. The analog signal conditioning circuit and the core controller are connected to each other. The auxiliary module includes an F-RAM memory for storing and reading configuration information and a precision voltage reference source for providing a voltage reference source to the core controller. The F-RAM memory and the core controller are connected to each other. The analog channel includes a precision current loop driver for outputting analog current signals, a precision voltage driver for outputting analog voltage signals, and an isolation combiner for combining the analog precision current loop driver and the precision voltage driver and outputting them to the outside through an M12-5 waterproof connector. The precision current loop driver and the precision voltage driver are respectively connected to the core controller, and the isolation combiner is respectively connected to the precision current loop driver, the precision voltage driver, and the M12-5 waterproof connector. The digital channel includes a high-side switch for outputting PNP open-drain type digital signals, a low-side switch for outputting NPN open-drain type digital signals, and an isolation combiner II for combining the high-side switch and the low-side switch and outputting them to the outside through an M12-5 core waterproof connector. The high-side switch and the low-side switch are respectively connected to the core controller, and the isolation combiner II is respectively connected to the high-side switch, the low-side switch, and the M12-5 core waterproof connector. The communication channel includes an IO-Link interface circuit, which is connected to the core controller and to an M12-5 waterproof connector via an EMC network.

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