Preparation method of particle sensor shell based on real gravel form and material

Abstract

The invention provides a preparation method of a particle sensor shell based on a real gravel form and material, and belongs to the field of particle sensor preparation. The invention aims to overcome the limitation on shape and material in the prior art and provide a more real and effective measurement environment for a particle sensor so as to remarkably improve the measurement accuracy of physical information of crushed stone materials. The method is characterized by comprising the steps of designing and manufacturing a gravel mold, manufacturing a sensor model, designing and constructing a telescopic supporting frame, precisely assembling and preprocessing the mold, precisely pouring and forming, and precisely splicing and assembling a shell. According to the technology, the natural form and material characteristics of real gravel are fused, a lifelike and practical protective shell is provided for the sensor, the firmness and durability of the shell are guaranteed, and the signal received by the internal sensor more truly and accurately represents the physical information of the granular material, so that the sensor can be used for detecting the physical information of the granular material. And a new solution is provided for the application of the particle sensor.

Description

[Technical field]

[0003] The present invention relates to the field of particle sensor preparation, and in particular to a method for preparing a particle sensor shell based on the shape and material of real gravel. [Background technology]

[0004] In the construction and maintenance of transportation infrastructure, granular materials such as crushed stone are widely used due to their good mechanical properties and stability, especially in key areas such as roads and railways. In order to comprehensively and accurately evaluate the service performance of crushed stone in these infrastructures, it is usually necessary to measure and collect physical information deep inside the granules. At this time, the sensor is the core tool, and its performance and adaptability directly affect the accuracy and reliability of the measurement results. However, granular materials, especially crushed stone, have a significant impact on the generation and transmission of physical information with their complex and changeable irregular geometric shapes and unique material properties. Therefore, in order to accurately and efficiently capture the physical information of granular materials, the design of the sensor housing needs to fully consider these factors. Ideally, the shape and material of the sensor housing should be as close to the real particles as possible to minimize the interference of the housing on the measurement of physical information and improve the accuracy and effectiveness of the measurement. However, the existing technology still has significant limitations in this field. The traditional preparation method of particle sensor housing mainly relies on regular shapes such as cuboids and cylinders. These shapes are significantly different from the irregular shapes of real crushed stone, and it is difficult to accurately reflect the real physical behavior of granular materials. In recent years, with the development of 3D printing technology, although it has made it possible to prepare irregularly shaped particle sensor shells, these shells are still quite different from real gravel in terms of material due to the types and properties of printing materials. This difference not only affects the durability and adaptability of the shell, but more importantly, it limits the sensor's ability to accurately capture the real physical information of granular materials such as gravel, thereby affecting the accuracy and reliability of the measurement results. In response to this technical problem, the present invention proposes an innovative method for preparing a particle sensor shell, which can prepare a particle sensor shell with a real gravel geometry and material, which not only overcomes the limitations of the prior art in shape and material, but also provides a more realistic and effective measurement environment for particle sensors, which can significantly improve the accuracy of measuring the physical information of gravel, and provide more reliable technical support for the monitoring and maintenance of transportation infrastructure. [Summary of the invention]

[0005] The present invention relates to an innovative particle sensor housing preparation technology, which combines the natural morphology and material properties of real gravel to provide a realistic and practical protective housing for the sensor. Specifically, the present invention proposes a particle sensor housing preparation method based on the morphology and material of real gravel, which includes the following six key steps:

[0006] 1. Design and production of gravel mold:

[0007] Using real gravel as a design prototype, two rectangular gravel molds with sizes slightly larger than real gravel were made. One side of the two molds was designed to be open, and its shape precisely matched the geometric shape of real gravel, ensuring that when the two molds were fitted together according to the open surface, the hollow space formed inside could accurately accommodate the gravel. This design not only retained the natural shape of the gravel, but also ensured that the shape of the final particle sensor housing was highly consistent with the geometric shape of the real gravel.

[0008] 2. Production of sensor model:

[0009] According to the actual size of the target particle sensor, a rectangular sensor model with a size slightly larger than the real sensor is made through precise measurement. The model has rectangular support rods extending from the center of the front, back, left and right surfaces. These support rods play a key role in fixing and supporting in the subsequent steps to ensure the stability of the sensor during the casting process.

[0010] 3. Design and construction of retractable support frame:

[0011] The present invention designs a support frame that fully matches the size of the bottom surface of the gravel mold, and its bottom can fit tightly against the bottom surface of the gravel mold. Retractable "L"-shaped telescopic rods are arranged at the center of the edges of the support frame. These telescopic rods can be flexibly adjusted in the horizontal direction to accommodate sensor models of different sizes. At the same time, a hollow space is reserved at the top of the "L"-shaped telescopic rod, providing a precise position for embedding the sensor model.

[0012] 4. Precision assembly and pretreatment of molds:

[0013] Lay a thin layer of isolation medium inside the open part of the gravel mold, and use real gravel to gently press the isolation medium to ensure that the isolation medium is completely embedded in the gap between the gravel and the gravel mold to form an isolation layer. Install the retractable support frame at the bottom of the gravel mold, and accurately insert the support rod extending from the sensor model into the hollow space at the top of the "L"-shaped telescopic rod of the support frame. By adjusting the "L"-shaped telescopic rods around, the retractable support frame fits tightly against the side of the gravel mold, thereby fixing the gravel mold and preparing for the subsequent pouring steps.

[0014] 5. Precision casting and molding process:

[0015] The gravel mold with the assembled retractable support frame is stably placed on a horizontal platform. The present invention adopts a fast-curing casting made of a mixture of ultrafine cement, ultrafine quartz sand and small-particle gravel. The casting is injected at a uniform and slow speed, and combined with the process of vibration and surface flattening, to ensure that the casting is evenly distributed and tightly fills the open part of the gravel mold. During the pouring process, pay attention to the coverage of the sensor model to ensure that the casting completely covers half of the sensor model. After the casting is completely cured, remove the gravel mold, the retractable support frame, the sensor model and the isolation medium to obtain a sensor housing (half) with a reserved sensor embedding space. Repeat steps 4 and 5 to make another sensor housing (half) with a reserved sensor embedding space.

[0016] 6. Precision splicing and assembly of the shell:

[0017] The actual sensor is placed in the reserved embedding space, and the two parts of the cast shell are precisely bonded together using a high-performance adhesive. The integrity and stability of the shell are ensured through precise splicing and assembly processes, thus preparing a complete particle sensor shell.

[0018] Through the above steps, the present invention successfully integrates the shape and material of real gravel into the preparation of the shell of the particle sensor, which not only improves the concealment and environmental adaptability of the sensor, ensures the firmness and durability of the shell, but also makes the signal received by the internal sensor more realistically and accurately represent the physical information of the particle material, providing a new solution for the application of particle sensors.

Brief Description of the Drawings

[0019] Figure 1 Schematic diagram of a gravel mold made using real gravel.

[0020] Figure 2 Schematic diagram of the sensor model designed for the present invention.

[0021] Figure 3 Schematic diagram of the retractable support frame designed for the present invention.

[0022] Figure 4 Schematic diagram of the assembly and casting of the gravel mold, retractable support frame and sensor model.

[0023] Figure 5 This is a schematic diagram of the sensor housing assembly. [Specific implementation method]

[0024] The technical solution of the present invention is further described in detail below through examples and in combination with the accompanying drawings. The following examples are used to further illustrate the present invention, but are not intended to limit the scope of the claims of the present invention. As an example, the method for preparing a particle sensor housing having a real gravel shape and material proposed by the present invention comprises the following steps:

[0025] 101 Design and production of gravel mold;

[0026] Select a real gravel and place it stably on the table. Use a measuring tool to measure vertically from the bottom of the gravel to its highest point and record the height value as H. Measure a distance of H / 2 upward from the bottom of the gravel and mark the corresponding position on the surface of the gravel. Draw a circle around this mark as the central axis of the gravel. The gravel is cut in half along the central axis to obtain two halves of gravel; the two halves of gravel respectively have a flat cross-section and an uneven outer surface; the flat cross-section of one half of the real gravel is stably placed on the printing platform at the bottom of the 3D printer, and 3D printing is performed along its outer surface to print out a hollow rectangular gravel mold that completely covers the half of the real gravel; after the printing material is solidified, the half of the real gravel inside the hollow rectangular gravel mold is taken out to obtain a gravel mold 11 containing an open part, and the shape of the open part of the gravel mold 11 is the same as the shape of the outer surface of the half of the real gravel; the same method can be used to obtain a gravel mold 12 containing an open part by 3D printing using the other half of the real gravel; the hollow space formed by the gravel molds 11 and 12 being fitted together according to the open surfaces can just accurately accommodate the real gravel.

[0027] If there is no 3D printing equipment, the following method can also be used to make the gravel mold: fill an open-top rectangular container with oil-based clay, the size of the rectangular container must be larger than the real gravel used; mark the central axis of the outer surface of the real gravel, pad one side of the gravel with a layer of PVC film and slowly press it into the oil-based clay until the central axis of the real gravel just fits with the open surface of the rectangular container; remove the oil-based clay squeezed out of the rectangular container, take out the real gravel, and obtain a gravel mold 11 with a PVC film laid on the open part, the shape of the open part of the gravel mold 11 is the same as the shape of the outer surface on one side of the central axis of the real gravel; the same method can be used to use the real gravel with the central axis marked to make a gravel mold 12 containing an open part; the hollow space formed by the gravel molds 11 and 12 after the open surfaces are fitted together can just accurately accommodate the real gravel.

[0028] 102 sensor model making;

[0029] The length, width and height (H) of the real target sensor are measured, and a sensor model 21 with the same length and width but greater height than the target sensor is produced, and a rectangular support rod 22 extending outward is fixed to the front, rear, left and right sides of the sensor model 21 respectively; the height of the rectangular support rod 22 is h, and the height of the sensor model 21 should be H+h, to ensure that the height from the lower edge of the rectangular support rod 22 to the lower edge of the sensor model 21 is H / 2, so that the height of the lower suspended part of the sensor model 21 after assembly in the subsequent steps is half the height of the real target sensor, that is, H / 2.

[0030] 103 Design and construction of retractable support frame;

[0031] A retractable support frame 3 consisting of a support frame bottom plate 31 and an "L"-shaped retractable rod 32 is manufactured; the length and width of the support frame bottom plate 31 are respectively the same as the length and width of the non-open surface of the bottom of the crushed stone mold 11; "L"-shaped retractable rods 32 are respectively manufactured at the centers of the four sides of the support frame bottom plate 31; the "L"-shaped retractable rod 32 is composed of a retractable rod 321 and a rectangular plate 322 with a square hole on the top; the height of the rectangular plate 322 is designed to be higher than the height of the crushed stone mold 11, ensuring that the bottom height of the square hole on the top of the rectangular plate 322 is the same as the height of the crushed stone mold 11, and the size of the hole is determined according to the length and width of the rectangular support rods 22 extending from the four sides of the sensor model 21, ensuring that the square hole on the top of the rectangular plate 322 and the rectangular support rod 22 can be firmly connected.

[0032] 104 mold assembly and pretreatment;

[0033] A layer of PVC film is placed in the open part of the gravel mold 11. The size of the PVC film should completely cover the open part of the gravel mold 11. The real gravel is gently pressed to make the PVC film fit tightly with the inner groove of the gravel mold. If the gravel mold is made of oil-based clay, the PVC film placement step can be skipped.

[0034] Pull open the "L"-shaped telescopic rods 32 around the telescopic support frame 3, place the gravel mold 11 on the support frame bottom plate 31, and make the bottom of the gravel mold 11 completely overlap with the support frame bottom plate 31; extend the four rectangular support rods 22 extending outward from the sensor model 21 into the square holes on the top of the rectangular plate 322 in the "L"-shaped telescopic rods 32, and then retract the telescopic rods 321 to make the rectangular plate 322 close to the side of the gravel mold 11, so that the lower half of the sensor model 21 is suspended in the top space of the open part of the gravel mold 11. At this time, the volume of the sensor model 21 suspended below the top of the gravel mold 11 is half of the volume of the real target sensor.

[0035] 105 casting molding;

[0036] After the quick-setting ultrafine cement, ultrafine quartz sand and small-size crushed stone are mixed to form a casting, the casting is slowly and evenly injected into the open part of the crushed stone mold 11. During the injection, the casting is vibrated, stirred and spread evenly with a vibrating rod to completely fill the open part of the crushed stone mold 11. The surface is flattened with a scraper and then left to stand for the casting to solidify.

[0037] Pull open the "L"-shaped telescopic rod 32 of the telescopic support frame 3, remove the sensor model 21, invert the gravel mold 11, and make the solidified casting separate from the gravel mold 11 to obtain a sensor housing 41 (half) with a reserved space for embedding a target sensor; use the gravel mold 12 to repeat steps 104 and 105 to make another sensor housing 42 (half) with a reserved space for embedding a target sensor.

[0038] 106 Shell splicing and assembly;

[0039] Place the real target sensor in the space reserved for the sensor housing 41, evenly apply adhesive, such as epoxy resin or polyurethane adhesive, on the fitting surfaces of the housings 41 and 42, fit the two housings together, and precisely bond the two parts of the cast housing together to prepare a complete particle sensor housing 4; the geometry and material of the particle sensor housing 4 are very close to real gravel.

[0040] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for preparing a particle sensor housing based on the shape and material of real gravel, characterized in that The following steps are involved: a. Design and production of gravel molds: Design and produce two gravel molds based on real gravel. One side of the mold is designed to be open, and the shape accurately matches the geometric shape of real gravel to form a hollow space that can accurately accommodate the gravel; b. Fabrication of sensor model: Fabricate a sensor model that is slightly larger than the real sensor. The four surfaces of the model are equipped with support rods for fixing to ensure its stability during the pouring process. c. Design and construction of a retractable support frame: Design and construct a retractable support frame that matches the bottom surface of the gravel mold. The support frame is provided with a retractable "L"-shaped telescopic rod, and a hole is reserved at the top of the "L"-shaped telescopic rod for embedding the support rod of the sensor model to fix the sensor model; d. Precision assembly and pretreatment of the mold: lay the isolation medium inside the open surface of the gravel mold, install the support frame, and insert the support rod of the sensor model into the "L"-shaped telescopic rod opening of the support frame, and adjust the telescopic rod to make the support frame fit tightly with the side of the gravel mold; e. Precision casting and molding process: Use fast-curing castings to inject into the open part of the mold to cover half of the sensor model. After the castings are cured, remove the mold, support frame, sensor model and isolation medium to obtain a sensor housing (half) with a reserved sensor embedding space. Repeat steps d and e to make another housing (half); f. Precision splicing and assembly of the shell: Fix the real sensor in the reserved embedding space, use high-performance adhesive to bond the two parts of the shell together to complete the preparation of the particle sensor shell.

2. The preparation method according to claim 1, characterized in that: The gravel mold can be made by 3D printing, or by placing a thin isolation medium under the real gravel and pressing the gravel and the isolation medium into a mold filled with oil-based clay to form an open part that matches the surface shape of the real gravel.

3. The preparation method according to claim 1, characterized in that The sensor model is designed such that support rods extend from four sides of the sensor model so that the sensor model can be supported in the opening of the gravel mold.

4. The preparation method according to claim 1, characterized in that The design of the retractable support frame is that retractable "L"-shaped telescopic rods are designed at the centers of the four sides of the support frame bottom plate.

5. The preparation method according to claim 1, characterized in that The "L"-shaped telescopic rod is designed in such a way that the bottom of the telescopic rod is connected to the bottom plate of the telescopic support frame and can be telescopically adjusted. A hole is reserved at the top of the telescopic rod for the support rod of the sensor model to extend into, so as to ensure that the sensor model can be stably suspended above the gravel mold.

6. The preparation method according to claim 1, characterized in that: Before pouring, a layer of isolation medium is laid inside the gravel mold to facilitate separation of the pouring from the mold after solidification.

7. The preparation method according to claim 1, characterized in that The casting is made of a mixture of ultra-fine cement, quartz sand and small-diameter crushed stone, and has the characteristics of rapid solidification and high strength.

8. The preparation method according to claim 1, characterized in that The selection and use of the high-performance adhesive may be epoxy resin or polyurethane adhesive, which may be evenly applied to the joint surface of the shell to ensure the strength and sealing of the joint of the shell.

Images