A preparation method for the housing of a particle sensor based on the actual gravel morphology and material

Abstract

The present invention provides a method for preparing a particle sensor housing based on the true morphology and material of crushed stones, belonging to the field of particle sensor preparation. The aim is to overcome the limitations in shape and material of the prior art, provide a more realistic and effective measurement environment for the particle sensor, and significantly improve the accuracy of measuring the physical information of crushed stone materials. Its features include the design and fabrication of a crushed stone mold, the fabrication of a sensor model, the design and construction of a telescopic support frame, the precise assembly and pre-treatment of the mold, the precise pouring and molding process, and the precise splicing and assembly of the housing. This technology integrates the natural morphology and material characteristics of true crushed stones, provides a realistic and practical protective housing for the sensor, ensures the firmness and durability of the housing, and enables the signals received by the internal sensor to more accurately and realistically represent the physical information of the particulate material, providing a new solution for the application of particle sensors.

Description

Technical Field

[0001] The present invention relates to the field of preparation of particle sensors, and particularly to a method for preparing a particle sensor housing based on the true morphology and material of crushed stones.

Background Art

[0002] In the construction and maintenance of transportation infrastructure, granular materials such as crushed stones are widely used due to their good mechanical properties and stability, especially in key fields such as roads and railways. To comprehensively and accurately evaluate the service performance of crushed stones in these infrastructures, it is usually necessary to measure and collect physical information deep inside the granular body. At this time, as the core tool, the performance and adaptability of the sensor directly affect the accuracy and reliability of the measurement results. However, granular materials, especially crushed stones, with their complex and variable irregular geometric shapes and unique material properties, have a significant impact on the generation and transmission of physical information. 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 as possible to the real particles to minimize the interference of the housing on the physical information measurement and improve the accuracy and effectiveness of the measurement. However, there are still significant limitations in the prior art in this field. The traditional methods for preparing particle sensor housings mainly rely on regular shapes such as cuboids and cylinders, which are significantly different from the irregular shapes of real crushed stones and are difficult to accurately reflect the true physical behavior of granular materials. In recent years, with the development of 3D printing technology, although it has made it possible to prepare particle sensor housings with irregular shapes, limited by the types and properties of printing materials, there are still large differences between these housings and real crushed stones in terms of material. This difference not only affects the durability and adaptability of the housing, but more importantly, limits the accurate capture of the true physical information of granular materials such as crushed stones by the sensor, thus affecting the accuracy and reliability of the measurement results. To address this technical problem, the present invention proposes an innovative method for preparing a particle sensor housing, which can prepare a particle sensor housing with the true geometric shape and material of crushed stones, not only overcoming the limitations in shape and material of the prior art, but also providing a more real and effective measurement environment for the particle sensor, significantly improving the accuracy of the physical information measurement of crushed stones, and providing more reliable technical support for the monitoring and maintenance of transportation infrastructure.

Summary of the Invention

[0003] The present invention relates to an innovative technology for preparing a particle sensor housing, which integrates the natural morphology and material characteristics of real crushed stones to provide a realistic and practical protective housing for the sensor. Specifically, the present invention proposes a method for preparing a particle sensor housing based on the true morphology and material of crushed stones, which includes the following six key steps:

[0004] 1. Design and fabrication of gravel molds:

[0005] Using real gravel as the design prototype, two rectangular gravel molds slightly larger in size than the real gravel are fabricated. One side of these two molds is designed to be open, and its shape precisely matches the geometric shape of the real gravel, ensuring that when the two molds are fitted together with the open sides facing each other, the hollow space formed inside can precisely accommodate the gravel. This design not only preserves the natural form of the gravel but also ensures that the outer shape of the final prepared particle sensor housing is highly consistent with the geometric form of the real gravel.

[0006] 2. Fabrication of the sensor model:

[0007] According to the actual size of the target particle sensor, through precise measurement, a rectangular sensor model slightly larger than the real sensor is fabricated. Rectangular support rods extend from the center positions of the front, back, left, and right surfaces of this model. These support rods play a crucial role in fixing and supporting in subsequent steps, ensuring the stability of the sensor during the pouring process.

[0008] 3. Design and construction of the retractable support frame:

[0009] The present invention designs a support frame that exactly matches the bottom size of the gravel mold, and its bottom can closely fit the bottom surface of the gravel mold. Retractable "L"-shaped telescopic rods are provided at the centers of the four peripheral edges of the support frame. These telescopic rods can be flexibly adjusted in the horizontal direction to adapt to sensor models of different sizes. At the same time, a hollow space is reserved at the top of the "L"-shaped telescopic rods, providing an accurate position for the embedding of the sensor model.

[0010] 4. Precision assembly and pretreatment of the mold:

[0011] Inside the open part of the gravel mold, a thin isolation medium is laid, and the real gravel is used to gently press the isolation medium to ensure that the isolation medium is completely embedded in the gaps between the gravel and the gravel mold, forming an isolation layer. The retractable support frame is installed at the bottom of the gravel mold, and the support rods extending from the sensor model are precisely inserted into the hollow spaces at the tops of the "L"-shaped telescopic rods of the support frame. By adjusting the "L"-shaped telescopic rods around, the retractable support frame is made to closely fit the side surfaces of the gravel mold, thereby fixing the gravel mold and preparing for the subsequent pouring step.

[0012] 5. Precision pouring and molding process:

[0013] Stably place the gravel mold with the assembled retractable support frame on a horizontal platform. The present invention uses a fast-curing casting material composed of ultra-fine cement, ultra-fine quartz sand, and small-sized gravel. By injecting the casting material uniformly and slowly, and combining the processes of vibration and surface scraping, ensure that the casting material is evenly distributed and tightly fills the open part of the gravel mold. During the casting process, pay attention to the coverage of the sensor model to ensure that the casting material completely covers half of the sensor model. After the casting material is completely cured, remove the gravel mold, retractable support frame, sensor model, and isolation medium, and a sensor housing (half) with a reserved sensor embedding space can be obtained. Repeat steps 4 and 5 to make another sensor housing (half) with a reserved sensor embedding space.

[0014] 6. Precision splicing and assembly of the housing:

[0015] Place the real sensor in the reserved embedding space, and use a high-performance adhesive to accurately bond and adhere the two parts of the cast housing together. Through precise splicing and assembly processes, ensure the integrity and stability of the housing, thereby preparing a complete particle sensor housing.

[0016] Through the above steps, the present invention has successfully realized integrating the shape and material of real gravel into the preparation of the particle sensor housing, not only improving the concealment and environmental adaptability of the sensor, ensuring the firmness and durability of the housing, but also enabling the signals received by the internal sensor to more truly and accurately represent the physical information of the particulate material, providing a new solution for the application of the particle sensor.

Description of the Drawings

[0017] Figure 1 Schematic diagram of the gravel mold made of real gravel.

[0018] Figure 2 Schematic diagram of the sensor model designed by the present invention.

[0019] Figure 3 Schematic diagram of the retractable support frame designed by the present invention.

[0020] Figure 4 Schematic diagram of the assembly and casting of the gravel mold, retractable support frame, and sensor model.

[0021] Figure 5 Schematic diagram of the splicing of the sensor housing.

Detailed Implementation Modes

[0022] The technical solution of the present invention will be further specifically described below through embodiments in conjunction with the accompanying drawings. The following examples are used to further illustrate the present invention rather than limiting the scope defined by the claims of the present invention. As an embodiment, the preparation method of the particle sensor housing with real gravel shape and material proposed by the present invention includes the following steps:

[0023] 101 Design and manufacture of gravel molds;

[0024] Select real gravel and place it stably on the tabletop. Use a measuring tool to measure vertically upward from the bottom of the gravel to its highest point, and record the height value as H. Measure the distance of H / 2 upward from the bottom of the gravel, and make a mark at the corresponding position on the surface of the gravel. Draw a circle of lines around this mark as the central axis of the gravel. Cut the gravel in half along the central axis to obtain two half pieces of gravel; each of the two half pieces of gravel has a flat cut surface and an uneven outer surface; stably place the flat cut surface of one half piece of real gravel on the bottom printing platform of the 3D printer, and perform 3D printing along its outer surface to print out a hollow cuboid gravel mold that completely covers the half piece of real gravel; after the printing material is cured, take out the half piece of real gravel inside the hollow cuboid gravel mold to obtain a gravel mold 11 with 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 piece of real gravel; the gravel mold 12 with an open part can be obtained by 3D printing using the other half piece of real gravel in the same way; the hollow space formed after the gravel molds 11 and 12 are attached by their open surfaces can exactly and accurately accommodate the real gravel.

[0025] If there is no 3D printing equipment, the gravel mold can also be made by the following method: fill a non-capped cuboid container with oil-based clay, and the size of the cuboid container needs to be larger than the real gravel used; make a mark at the central axis of the outer surface of the real gravel, pad a layer of PVC film on one side of the gravel and slowly press it into the oil-based clay until the central axis of the gravel just fits the open surface of the cuboid container; remove the oil-based clay extruded from the cuboid container, take out the real gravel, and obtain a gravel mold 11 with an open part where the PVC film has been laid, and 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 gravel mold 12 with an open part can be made using the real gravel marked with the central axis in the same way; the hollow space formed after the gravel molds 11 and 12 are attached by their open surfaces can exactly and accurately accommodate the real gravel.

[0026] 102 Manufacture of sensor models;

[0027] Measure the length, width, and height (H) of the real target sensor, and fabricate a sensor model 21 with the same length and width but a height greater than that of the target sensor. Fix a cuboid support rod 22 extending outward on the front, back, left, and right sides of the sensor model 21 respectively. The height of the cuboid 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 cuboid 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 of the height of the real target sensor, i.e., H / 2.

[0028] 103 Design and construction of a telescopic support frame;

[0029] Fabricate a telescopic support frame 3 composed of a support frame bottom plate 31 and an "L"-shaped telescopic rod 32. The length and width of the support frame bottom plate 31 are the same as the length and width of the non-open surface at the bottom of the gravel mold 11 respectively. Make "L"-shaped telescopic rods 32 at the centers of the four sides of the support frame bottom plate 31 respectively. The "L"-shaped telescopic rod 32 is composed of a telescopic rod 321 and a cuboid plate 322 with a square hole at the top. The height of the cuboid plate 322 is designed to be higher than the height of the gravel mold 11 to ensure that the bottom edge height of the square hole at the top of the cuboid plate 322 is the same as the height of the gravel mold 11, and the size of the hole is determined according to the length and width of the cuboid support rod 22 extending from the four sides of the sensor model 21 to ensure that the square hole at the top of the cuboid plate 322 can be stably docked with the cuboid support rod 22.

[0030] 104 Mold assembly and pretreatment;

[0031] Place a layer of PVC film in the open part of the gravel mold 11. The size of the PVC film needs to completely cover the open part of the gravel mold 11, and gently press it with the real gravel to make the PVC film closely fit the internal groove of the gravel mold. If the gravel mold is made of oil-based clay, the step of placing the PVC film can be skipped.

[0032] Pull out the "L"-shaped telescopic rods 32 around the telescopic support frame 3, place the gravel mold 11 on the support frame bottom plate 31 so that the bottom of the gravel mold 11 completely coincides with the support frame bottom plate 31. Insert the four cuboid support rods 22 extending outward from the sensor model 21 into the square holes at the top of the cuboid plates 322 in the "L"-shaped telescopic rods 32, and then retract the telescopic rods 321 to make the cuboid plates 322 closely adhere 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.

[0033] 105 Pouring and molding;

[0034] Mix the rapidly solidified ultra-fine cement, ultra-fine quartz sand and small-sized crushed stones to form a casting material, and then slowly and evenly inject it into the open part of the crushed stone mold 11. During injection, use a vibrating rod to vibrate, stir and level it to make the casting material completely fill the open part of the crushed stone mold 11. After scraping the surface flat with a scraper, let it stand until the casting material solidifies;

[0035] Pull open the "L"-shaped telescopic rod 32 of the retractable support frame 3, remove the sensor model 21, invert the crushed stone mold 11 to make the solidified casting material separate from the crushed stone mold 11, and obtain a sensor housing 41 (half) with a reserved embedding space for the target sensor; By using the crushed stone mold 12 and repeating steps 104 and 105, another sensor housing 42 (half) with a reserved embedding space for the target sensor can be made.

[0036] 106 Housing splicing and assembly;

[0037] Place the real target sensor in the reserved space of the sensor housing 41, evenly apply an adhesive, such as epoxy resin or polyurethane adhesive, on the mating surface of the housings 41 and 42, and then fit the two housings together to accurately bond the two housings obtained by casting to prepare a complete particle sensor housing 4; The geometric shape and material of the particle sensor housing 4 are very close to those of real crushed stones.

[0038] The above are only the embodiments of the present invention, and do not limit the patent scope of the present invention accordingly. Any equivalent structural or equivalent process transformation made by using the content of the specification and drawings of the present invention, or directly or indirectly applied in other related technical fields, shall be equally 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 reserved opening at the top of the "L"-shaped telescopic rod is used to embed the support rod of the sensor model and fix the sensor model. The bottom of the telescopic rod is connected to the bottom plate of the retractable support frame and can be retracted and adjusted. The top of the telescopic rod is reserved with an opening 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; 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 half sensor shell with a reserved sensor embedding space. Repeat steps d and e to make the other half of the shell; 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 is made by 3D printing, or after a thin layer of isolation medium is placed under the real gravel, the gravel and the isolation medium are pressed 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: Before pouring, a layer of isolation medium is laid inside the gravel mold to facilitate separation of the pouring from the mold after solidification.

6. 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.

7. 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.

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