Wireless ultrasonic sensing device and system applied to metal anchor rod detection

Abstract

The invention relates to the technical field of detection, and particularly discloses a wireless ultrasonic sensing device and system applied to metal anchor rod detection, and the device comprises a main controller, an ultrasonic module and a wireless communication module; the main controller generates PWM for driving the ultrasonic module to send out an ultrasonic signal; the ultrasonic module sends an ultrasonic signal to the metal anchor rod, receives a reflected feedback signal, processes the feedback signal and transmits the feedback signal to the main controller; the main controller calculates and determines the length of the metal anchor rod based on the information of the ultrasonic signal and the processed feedback signal; the main controller is further used for transmitting the calculated length information to the cloud platform through the wireless communication module so that the cloud platform can analyze the working state of the metal anchor rod to be measured. Thus, under the condition of low power consumption, the length of the metal anchor rod can be detected in real time with high precision, and the calculation result can be sent to the cloud platform through the wireless communication module, so that the working state of the metal anchor rod is determined through the cloud platform.

Description

Technical Field

[0001] The present invention relates to the field of detection technology, and in particular to a wireless ultrasonic sensor device and system used for metal anchor detection. Background Art

[0002] In mining, engineering, and mines and other related fields, anchor rods, especially metal anchor rods, are a widely used support tool, mainly used to reinforce the surrounding rock of tunnels, thereby enhancing the strength and stability of the rock mass. When the anchor rod is inserted into the rock mass and anchored, it can connect the broken rocks in series, just like putting on "armor" for the tunnel, effectively resisting the deformation and damage of the surrounding rock, and preventing accidents such as roof sinking and spalling. In engineering applications, whether the anchor rod is normal is directly related to the safety of production. Once the anchor rod fails, it will bring risks to the reinforced tunnel and threaten the stability of the surrounding rock. However, due to the harsh working conditions on site, it is easy to cause risks such as anchor rod stretching and fracture. Therefore, real-time detection of the working status of the anchor rod is of great significance to safe production.

[0003] There are also detection methods for such reinforcement and / or support tools in the prior art, such as the acoustic stress wave method and the optical fiber method. Among them, the acoustic stress wave method mostly uses a small hammer to knock and vibrate to generate stress waves, and its detection results are easily deviated due to different knocking forces; the optical fiber method is mostly used for anchor force detection, which has high requirements for welding processing, needs to be pre-buried, is not easy to operate, and the sensors and dynamometers used for detection are easily affected by the environment. Therefore, there is an urgent need for a small-sized, low-power, low-cost, real-time and high-precision wireless sensing device. Summary of the invention

[0004] In view of this, an object of the present invention is to provide a wireless ultrasonic sensing device and system for metal anchor detection, so as to overcome the problems of high power consumption and poor accuracy in current anchor detection.

[0005] To achieve the above objectives, the present invention adopts the following technical solutions:

[0006] In a first aspect, the present application provides a wireless ultrasonic sensing device for metal anchor detection, comprising: a main controller, an ultrasonic module and a wireless communication module;

[0007] The main controller is used to generate a PWM signal for driving the ultrasonic module to emit an ultrasonic signal;

[0008] The ultrasonic module is used to send an ultrasonic signal to the metal anchor rod to be tested under the drive of the PWM signal, receive a feedback signal reflected by the metal anchor rod to be tested, and process the feedback signal before transmitting it to the main controller;

[0009] The main controller is also used to calculate and determine the length of the metal anchor rod to be tested based on the information of the ultrasonic signal and the processed feedback signal;

[0010] The main controller is also used to transmit the length of the metal anchor rod to be tested to a preset cloud platform through the wireless communication module, so that the cloud platform can analyze the working status of the metal anchor rod to be tested.

[0011] Further, in some embodiments of the present application, the ultrasound module includes an ultrasound transmitting module and an ultrasound signal processing module both connected to the main controller;

[0012] The ultrasonic transmitting module is used to generate the ultrasonic signal under the drive of the PWM signal, and the ultrasonic signal processing module is used to receive the feedback signal, filter and amplify the feedback signal, and transmit the filtered and amplified signal to the main controller.

[0013] Furthermore, in some embodiments of the present application, the ultrasonic transmitting module includes a high-voltage excitation transducer, and the ultrasonic signal processing module includes an ultrasonic transducer.

[0014] Furthermore, in some embodiments of the present application, the wireless ultrasonic sensing device is provided with one end of the ultrasonic module for fixing the metal anchor rod to be tested, and the end of the wireless ultrasonic sensing device away from the ultrasonic module is provided with a mounting structure, and the mounting structure is used to fix the wireless ultrasonic sensing device.

[0015] Furthermore, in some embodiments of the present application, a metal casing is also included.

[0016] Furthermore, in some embodiments of the present application, the wireless communication module includes one or more of a Bluetooth module, an RFID module, a Lora module, a NB-IoT module, a 4G module, a 5G module and a star light wireless communication module.

[0017] Further, in some embodiments of the present application, the main controller calculates and determines the length of the metal anchor to be measured based on the information of the ultrasonic signal and the processed feedback signal using the formula:

[0018] L = VxΔT / 2;

[0019] Wherein, L is the length of the metal anchor to be tested, v is the propagation speed of sound waves in metal, and ΔT is the time interval between sending the ultrasonic signal and receiving the feedback signal.

[0020] Furthermore, in some embodiments of the present application, a magnetic field sensor connected to the main controller is also included.

[0021] Furthermore, in some embodiments of the present application, a distance measuring sensor connected to the main controller is also included.

[0022] In a second aspect, the present application provides a wireless ultrasonic sensing system for metal anchor detection, characterized in that it comprises: the wireless ultrasonic sensing device for metal anchor detection and a cloud platform as described above;

[0023] The wireless ultrasonic sensor device is used to detect the length of the anchor rod to be tested, and send the calculated length information to the cloud platform;

[0024] The cloud platform uses the length calculated in real time by the wireless ultrasonic sensor device and the historical length information to analyze and determine the working status of the anchor rods to be tested.

[0025] The present invention relates to the field of detection technology, and in particular to a wireless ultrasonic sensing device and system for metal anchor detection, the device comprising a main controller, an ultrasonic module and a wireless communication module; wherein the main controller is used to generate a PWM signal for driving the ultrasonic module to send an ultrasonic signal; the ultrasonic module is used to send an ultrasonic signal to the metal anchor to be detected under the drive of the PWM signal, and receive a feedback signal reflected by the metal anchor to be detected, and transmit the feedback signal to the main controller after processing; the main controller is also used to calculate and determine the length of the metal anchor to be detected based on the information of the ultrasonic signal and the processed feedback signal; the main controller is also used to transmit the length of the metal anchor to be detected to a preset cloud platform through the wireless communication module, so that the cloud platform analyzes the working state of the metal anchor to be detected. In this way, the length of the metal anchor can be detected in real time with high precision under low power consumption, and the calculation result can also be sent to the cloud platform through the wireless communication module, so as to determine the working state of the metal anchor through the cloud platform. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0027] Figure 1 It is a schematic diagram of the structure of a wireless ultrasonic sensor device for metal anchor detection provided by an embodiment of the present invention.

[0028] Figure 2 It is a schematic diagram of the structure of a wireless ultrasonic sensor device for metal anchor detection provided by an embodiment of the present invention.

[0029] Figure 3It is a schematic diagram of the propagation of ultrasonic signals in the metal anchor to be tested.

[0030] Figure 4 It is a schematic diagram of the operating principle of an ultrasonic module in a wireless ultrasonic sensing device for metal anchor detection provided by an embodiment of the present invention.

[0031] Figure 5 It is a schematic diagram of the internal structure of a wireless ultrasonic sensor device for metal anchor detection provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0032] To make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be described in detail below. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other implementation methods obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention.

[0033] Figure 1 is a schematic diagram of the structure of a wireless ultrasonic sensor device for metal anchor detection provided by an embodiment of the present invention. Figure 1 The wireless ultrasonic sensing device for metal anchor detection in this embodiment may include a main controller, an ultrasonic module and a wireless communication module.

[0034] The main controller is used to generate a PWM signal, and the PWM is used to drive the ultrasonic module to send out an ultrasonic signal. The ultrasonic module is used to send out an ultrasonic signal to the metal anchor rod to be tested under the drive of the PWM signal, and receive the feedback signal reflected back by the metal anchor rod to be tested, and transmit the feedback signal to the main controller after processing; the main controller is also used to calculate and determine the length of the metal anchor rod to be tested based on the information of the ultrasonic signal and the processed feedback signal; the main controller is also used to transmit the length of the metal anchor rod to be tested to a preset cloud platform through the wireless communication module, so that the cloud platform can analyze the working status of the metal anchor rod to be tested.

[0035] The wireless ultrasonic sensing device for metal anchor rod detection provided in the present application can realize real-time and high-precision detection of the length of the metal anchor rod with low power consumption, and can also send the calculation results to the cloud platform through the wireless communication module, so as to determine the working status of the metal anchor rod through the cloud platform.

[0036] Figure 2 is a schematic diagram of the structure of a wireless ultrasonic sensor device for metal anchor detection provided by another embodiment of the present invention. Figure 2 In this embodiment, the wireless ultrasonic sensor device 1 includes a main controller 11, an ultrasonic probe 12, a radio frequency antenna 13, a power supply 14 and a mounting structure 15. Figure 2 2 in the middle is the metal anchor rod to be tested.

[0037] In this embodiment, the main controller 11 sends out PWM to drive the ultrasonic probe 12 to send out ultrasonic signals such as high-frequency ultrasound. The ultrasonic signal sent by the ultrasonic probe 12 will be emitted back after encountering an obstacle in the metal anchor to be tested. The ultrasonic probe 12 detects the echo signal and transmits it to the main controller 11 after processing it. The main controller 11 detects the processed signal and obtains the propagation time of the ultrasonic signal in the metal anchor, and then obtains the length of the metal anchor, such as the displacement information of the oil cylinder.

[0038] In the embodiment of the present application, the ultrasonic probe 12 is arranged on the top of the wireless ultrasonic sensor device. In actual application, it is fixedly arranged on the bottom of the metal anchor rod 2 to be tested. When the two are attached by a coupling agent, the ultrasonic probe introduces the ultrasonic signal into the metal anchor rod so that the ultrasonic signal propagates in the metal anchor rod. It can be understood that during the propagation process, when encountering a fracture or crack, the ultrasonic signal will be reflected, and the ultrasonic echo (i.e., feedback signal) will be detected by the ultrasonic probe again. For the specific process, please refer to Figure 3 At this time, the main control module can calculate the propagation time ΔT of the ultrasonic signal in the metal anchor rod 2 to be tested, and obtain the length L of the metal anchor rod, which can be calculated by the following formula:

[0039] L = VxΔT / 2;

[0040] In the above formula, V is the speed V at which sound waves propagate in metals, which is a constant and can be obtained through measurement in practical applications.

[0041] It should be noted that in the embodiment of the present application, a power supply 14 is also provided to power the entire wireless ultrasonic sensing device. It can be understood that because the above-mentioned models of the present application are all low-power, long-term power supply can be achieved through a separate power supply 14. It has been measured that a single battery can achieve a working time of no less than 3 years.

[0042] Furthermore, in the implementation of the present application, the wireless ultrasonic sensor device provided by the present application has a metal shell, and its protection level can meet the IP65 protection level. On this basis, threads and mounting structures can be set on the metal shell, such as at one end where the ultrasonic probe is set, the inner thread of the shell is fixedly connected to the metal anchor rod. In addition, according to the actual application on site, the wireless ultrasonic sensor device can be fixedly installed by using screws or the like through the mounting holes of the mounting structure provided at the end away from the ultrasonic probe. And, in other embodiments of the present application, the installation method of the wireless sensor device can also be achieved by gluing to fix the device to the rotating shaft.

[0043] Further, in some embodiments of the present application, the ultrasound module may include an ultrasound transmitting module and an ultrasound signal processing module both connected to the main controller; Figure 4 As shown, the ultrasonic transmitting module is used to generate an ultrasonic signal under the drive of a PWM signal, thereby completing the transmission of the ultrasonic signal; the ultrasonic signal processing module is used to receive a feedback signal, filter and amplify the feedback signal, and transmit the filtered and amplified signal to the main controller.

[0044] In practical applications, the ultrasonic transmitting module may include a high-voltage excitation transducer, and the ultrasonic signal processing module includes an ultrasonic transducer. In practical applications, the ultrasonic module is installed at the bottom of the metal anchor to be tested, and an ultrasonic signal is generated by the high-voltage excitation transducer. The ultrasonic signal is transmitted in the metal anchor and reflected at the end face of the other side of the metal anchor. The ultrasonic transducer will perform filtering, amplification and other processing, and the propagation time of the ultrasonic wave in the metal anchor is calculated by the main controller, thereby obtaining the length of the metal anchor.

[0045] In addition, in the present application, the wireless ultrasonic sensor device also includes a wireless communication module, which can use a circuit board microstrip antenna and be connected to the main control board of the main controller by a feeder. In practical applications, it can include one or more of a Bluetooth module, an RFID module, a Lora module, an NB-IoT module, a 4G module, a 5G module, and a star flash light wireless communication module. The length information calculated by the main control module is transmitted to the cloud platform through the wireless communication module.

[0046] It can be understood that in the present application, the wireless communication module, ultrasonic transmitting module, ultrasonic signal processing module and power supply mentioned above are all connected to the main controller for operation under the control of the main controller, as shown in FIG. Figure 5 shown.

[0047] In this application, the cloud platform can analyze and record the data transmitted by the wireless ultrasonic sensor device, such as recording the length information of each metal anchor at each time, and forming a record table for each metal anchor. Therefore, when a new real-time length information is received, it can be compared and analyzed with the saved historical length, thereby providing data basis for the normal operation, stretching and fracture of the metal anchor.

[0048] It is understandable that the wireless ultrasonic sensor device provided by the present application is low-cost and flexible in installation, can be deployed in large batches, and can omit wiring for wireless data transmission, and is simple to install and maintain. It can realize real-time and automatic detection of anchor length throughout the process, and the signal is transmitted wirelessly in real time, providing a basis for judging the working state of the metal anchor, such as normal, stretched, and broken, thereby improving production safety.

[0049] In addition, in other embodiments of the present application, multiple sensors can be added to the wireless ultrasonic sensing device to achieve multi-parameter monitoring, such as adding a magnetic field sensor to monitor changes in the surrounding magnetic field, and adding a ranging sensor to detect changes in the surrounding environment, so as to perform more comprehensive detection.

[0050] Based on the same inventive concept, the present invention also provides a wireless ultrasonic sensing system for metal anchor rod detection, which is used to implement the above-mentioned method embodiment, and the embodiment includes the wireless ultrasonic sensing device and cloud platform for metal anchor rod detection as mentioned above; the wireless ultrasonic sensing device is used to detect the length of the anchor rod to be tested, and send the calculated length information to the cloud platform; the cloud platform uses the length calculated in real time by the wireless ultrasonic sensing device and the historical length information to analyze and determine the working status of the anchor rod to be tested.

[0051] Regarding the system in the above embodiment, the specific manner in which each part performs operations has been described in detail in the embodiment of the device, and will not be elaborated here.

[0052] It can be understood that the same or similar parts of the above embodiments can be referenced to each other, and the contents not described in detail in some embodiments can refer to the same or similar contents in other embodiments.

[0053] It should be noted that, in the description of the present invention, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. In addition, in the description of the present invention, unless otherwise specified, the meaning of "plurality" refers to at least two.

[0054] Any process or method description in a flowchart or otherwise described herein may be understood to represent a module, segment or portion of code that includes one or more executable instructions for implementing the steps of a specific logical function or process, and the scope of the preferred embodiments of the present invention includes alternative implementations in which functions may not be performed in the order shown or discussed, including performing functions in a substantially simultaneous manner or in the reverse order depending on the functions involved, which should be understood by those skilled in the art to which the embodiments of the present invention belong.

[0055] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0056] A person skilled in the art may understand that all or part of the steps in the method for implementing the above-mentioned embodiment may be completed by instructing related hardware through a program, and the program may be stored in a computer-readable storage medium, which, when executed, includes one or a combination of the steps of the method embodiment.

[0057] In addition, each functional unit in each embodiment of the present invention may be integrated into a processing module, or each unit may exist physically separately, or two or more units may be integrated into one module. The above-mentioned integrated module may be implemented in the form of hardware or in the form of a software functional module. If the integrated module is implemented in the form of a software functional module and sold or used as an independent product, it may also be stored in a computer-readable storage medium.

[0058] The storage medium mentioned above can be a read-only memory, a magnetic disk or an optical disk, etc.

[0059] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0060] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A wireless ultrasonic sensor device for metal anchor detection, characterized in that: include: Main controller, ultrasound module and wireless communication module; The main controller is used to generate a PWM signal for driving the ultrasonic module to emit an ultrasonic signal; The ultrasonic module is used to send an ultrasonic signal to the metal anchor rod to be tested under the drive of the PWM signal, receive a feedback signal reflected by the metal anchor rod to be tested, and process the feedback signal before transmitting it to the main controller; The main controller is also used to calculate and determine the length of the metal anchor rod to be tested based on the information of the ultrasonic signal and the processed feedback signal; The main controller is also used to transmit the length of the metal anchor rod to be tested to a preset cloud platform through the wireless communication module, so that the cloud platform can analyze the working status of the metal anchor rod to be tested.

2. The wireless ultrasonic sensor device for metal anchor detection according to claim 1 is characterized in that: The ultrasonic module includes an ultrasonic transmitting module and an ultrasonic signal processing module, both of which are connected to the main controller; The ultrasonic transmitting module is used to generate the ultrasonic signal under the drive of the PWM signal, and the ultrasonic signal processing module is used to receive the feedback signal, filter and amplify the feedback signal, and transmit the filtered and amplified signal to the main controller.

3. The wireless ultrasonic sensor device for metal anchor detection according to claim 2 is characterized in that: The ultrasonic transmitting module includes a high-voltage excitation transducer, and the ultrasonic signal processing module includes an ultrasonic transducer.

4. The wireless ultrasonic sensor device for metal anchor detection according to claim 1 is characterized in that: The wireless ultrasonic sensor device is provided with one end of the ultrasonic module for fixing the metal anchor rod to be tested, and the end of the wireless ultrasonic sensor device away from the ultrasonic module is provided with a mounting structure, and the mounting structure is used to fix the wireless ultrasonic sensor device.

5. The wireless ultrasonic sensor device for metal anchor detection according to claim 1 is characterized in that: Also includes a metal housing.

6. The wireless ultrasonic sensor device for metal anchor detection according to claim 1 is characterized in that: The wireless communication module includes one or more of a Bluetooth module, an RFID module, a Lora module, a NB-IoT module, a 4G module, a 5G module and a star flash light wireless communication module.

7. The wireless ultrasonic sensor device for metal anchor detection according to claim 1 is characterized in that: The main controller calculates and determines the length of the metal anchor rod to be tested based on the information of the ultrasonic signal and the processed feedback signal using the formula: L = VxΔT / 2; Wherein, L is the length of the metal anchor to be tested, v is the propagation speed of sound waves in metal, and ΔT is the time interval between sending the ultrasonic signal and receiving the feedback signal.

8. The wireless ultrasonic sensor device for metal anchor detection according to claim 1, characterized in that: Also included is a magnetic field sensor connected to the main controller.

9. The wireless ultrasonic sensor device for metal anchor detection according to claim 1, characterized in that: Also included is a distance measuring sensor connected to the main controller.

10. A wireless ultrasonic sensing system for metal anchor detection, characterized in that: include: A wireless ultrasonic sensor device and a cloud platform for metal anchor detection as described in any one of claims 1 to 7; The wireless ultrasonic sensor device is used to detect the length of the anchor rod to be tested, and send the calculated length information to the cloud platform; The cloud platform uses the length calculated in real time by the wireless ultrasonic sensor device and the historical length information to analyze and determine the working status of the anchor rods to be tested.

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