Real-time detection method for liquid level volume in tank container

Abstract

The invention provides a real-time detection method for the liquid level volume in a tank container, and can solve the problems that the liquid level volume in the tank container cannot be detected in real time, the error is large and the workload is large in the existing method. The method comprises the following steps: sending first effective volume point cloud data and second effective volume point cloud data to a data processing unit; the effective volume of the tank container is calculated, and if the error between the effective volume and the theoretical volume is smaller than five thousandths, the first effective volume point cloud data and the second effective volume point cloud data are sent to a liquid level measuring device; the liquid level measuring device integrates the first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system to form effective volume point cloud data of the tank container; the liquid level meter measures the liquid level height in real time and sends the liquid level height to the liquid level measuring device; the liquid level measuring device integrates the real-time liquid level height into a coordinate system, and calculates and displays the real-time liquid level volume according to the effective volume point cloud data below the section where the real-time liquid level height is located.

Description

Technical Field

[0001] The invention relates to a method for detecting a liquid level volume in a container, and in particular to a real-time detection method for the liquid level volume in a tank container. Background Art

[0002] Tank containers are widely used in the storage and transportation of various types of liquids. Accurately grasping the liquid level and volume in the tank container is of vital importance for precise control of the production process, transportation safety, and cost accounting. For users, when delivering the medium shipped in the tank container, it is necessary to determine whether the shipping volume meets the design requirements by detecting the liquid level and volume, so as to ensure that the rights and interests of users are not harmed. The traditional liquid level and volume detection method is: the liquid level detection device on the tank container calibrates the liquid level height through artificial simulation, and then combines the shape and size parameters of the tank body to calculate the theoretical liquid level and volume. However, the problem with this method is that it cannot detect the liquid level and volume in the tank container in real time, the error is large, and the workload is large. Summary of the invention

[0003] The purpose of the present invention is to solve the technical problems that the existing liquid level volume detection method cannot detect the liquid level volume in a tank container in real time, has large errors and a large workload, and to provide a real-time detection method for the liquid level volume in a tank container.

[0004] In order to achieve the above object, the present invention adopts the following technical solution:

[0005] A real-time detection method for the liquid level volume in a tank container is characterized in that it comprises the following steps:

[0006] Step 1, calculate the effective volume of the tank container;

[0007] Step 1.1, using a laser three-dimensional scanning device to first scan the inner surface of the tank container except the reinforcement component to obtain first effective volume point cloud data, and then scan the outer surface of the reinforcement component to obtain second effective volume point cloud data, and then send the first effective volume point cloud data and the second effective volume point cloud data to an external data processing unit respectively;

[0008] Step 1.2, the data processing unit integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system, then connects adjacent points in the coordinate system into lines, and then performs surface reconstruction to form an actual model. The data processing unit calculates the effective volume of the tank container according to the actual model;

[0009] Step 1.3, determine the error between the effective volume and theoretical volume of the tank container;

[0010] If the error is less than 0.5%, the first effective volume point cloud data and the second effective volume point cloud data are respectively sent to the liquid level measuring device on the tank container, and step 2 is executed; otherwise, the tank container is returned for repair and the process returns to step 1.1;

[0011] Step 2: Real-time detection of the liquid level volume in the tank container;

[0012] Step 2.1, the liquid level measuring device integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system to form effective volume point cloud data of the tank container;

[0013] Step 2.2, filling or unloading the medium into the tank container, using the liquid level gauge in the tank container to measure the liquid level of the medium in real time and sending the liquid level to the liquid level measuring device;

[0014] Step 2.3, the liquid level measuring device integrates the received real-time liquid level height into the coordinate system of step 2.1, and then takes the cross section where the real-time liquid level height is located as a reference, calculates and displays the real-time liquid level volume according to the effective volume point cloud data below the cross section, and completes the real-time detection of the liquid level volume in the tank container.

[0015] Furthermore, step 2.1 specifically includes the following steps:

[0016] Step 2.1.1, the liquid level measuring device integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system to form initial effective volume point cloud data of the tank container;

[0017] Step 2.1.2: The liquid level measuring device calibrates the initial effective volume point cloud data formed in step 2.1.1 according to the display accuracy required by the liquid level measuring device, and screens out effective volume point cloud data that matches the display accuracy.

[0018] Furthermore, step 2.3 is specifically as follows:

[0019] The liquid level measuring device integrates the received real-time liquid level height into the coordinate system of step 2.1.1, and then uses the cross section where the real-time liquid level height is located as a reference, calculates and displays the real-time liquid level volume according to the effective volume point cloud data below the cross section that matches the display accuracy, and completes the real-time detection of the liquid level volume in the tank container.

[0020] Furthermore, step 1.2 specifically includes the following steps:

[0021] Step 1.2.1, the data processing unit integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system, then connects adjacent points in the coordinate system into lines, and then performs surface reconstruction, optimizes surface quality, and adds texture mapping to form an actual model;

[0022] Step 1.2.2, the data processing unit calculates the cylinder volume of the tank container, the volume of the two heads and the volume of the reinforcement component in the tank container according to the actual model formed in step 1.2.1, and then calculates the effective volume of the tank container according to the following formula:

[0023] The effective volume of the tank container = the volume of the cylinder + the volume of the two heads - the volume of the reinforcement component.

[0024] Beneficial effects of the present invention:

[0025] 1. The present invention provides a method for real-time detection of the liquid level volume in a tank container, which can detect the liquid level volume in the tank container in real time, with small errors and small workload. Among them, the method uses a laser three-dimensional scanning device to quickly obtain the effective volume point cloud data of the tank container, and combined with the data processing unit, it can calculate whether the effective volume of the tank container meets the requirements. The process has small workload, high efficiency and high accuracy. By associating the effective volume point cloud data obtained by the laser three-dimensional scanning device with the real-time liquid level height, the effect of real-time detection of the liquid level volume in the tank container can be achieved. In addition, the method of the present invention is applicable to special-shaped tank containers.

[0026] 2. In the present invention, the liquid level measuring device calibrates the effective volume point cloud data according to the display accuracy required by the liquid level measuring device, which can further improve the detection efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 1 is a schematic diagram of the connection structure between the tank container and the detection system in an embodiment of a method for real-time detection of liquid level volume in a tank container of the present invention (the data processing unit and the reinforcement component are not shown);

[0028] Figure 2 Schematic diagram of the structure when detecting the liquid level volume in an embodiment of the present invention (the reinforcement component is not shown).

[0029] Description of reference numerals:

[0030] 1-tank container, 2-laser three-dimensional scanning device, 3-liquid level meter, 4-liquid level measuring device. DETAILED DESCRIPTION

[0031] A real-time detection method for the liquid level volume in a tank container, using Figure 1The detection system shown in the figure comprises a liquid level measuring device 4 arranged on the outer wall of the tank container 1, a liquid level meter 3 connected to the liquid level measuring device 4, a laser three-dimensional scanning device 2 connected to the liquid level measuring device 4, and a data processing unit connected to the laser three-dimensional scanning device 2 and located outside the tank container 1, wherein the liquid level meter 3 is vertically arranged inside the tank container 1, and comprises the following steps:

[0032] Step 1, calculating the effective volume of the tank container 1;

[0033] Step 1.1, using a laser three-dimensional scanning device 2 to first scan the inner surface of the tank container 1 except the reinforcement component to obtain first effective volume point cloud data, and then scan the outer surface of the reinforcement component to obtain second effective volume point cloud data, and then send the first effective volume point cloud data and the second effective volume point cloud data to an external data processing unit respectively;

[0034] Step 1.2.1, the data processing unit integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system, then connects adjacent points in the coordinate system into lines, and then performs surface reconstruction, optimizes surface quality, and adds texture mapping to form an actual model;

[0035] Step 1.2.2, the data processing unit calculates the cylinder volume of the tank container 1, the volume of the two heads and the volume of the reinforcement component in the tank container 1 according to the actual model formed in step 1.2.1, and then calculates the effective volume of the tank container 1 according to the following formula:

[0036] The effective volume of the tank container 1 = the volume of the cylinder + the volume of the two heads - the volume of the reinforcement assembly;

[0037] Step 1.3, determining the error between the effective volume and theoretical volume of the tank container 1 obtained in step 1.2.2;

[0038] If the error is less than 0.5%, the first effective volume point cloud data and the second effective volume point cloud data are respectively sent to the liquid level measuring device 4 on the tank container 1, and step 2 is executed; otherwise, the tank container 1 is returned for repair and the process returns to step 1.1.

[0039] Step 2: Real-time detection of the liquid level volume in the tank container 1;

[0040] Step 2.1.1, the liquid level measuring device 4 integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system to form initial effective volume point cloud data of the tank container 1;

[0041] Step 2.1.2, the liquid level measuring device 4 calibrates the initial effective volume point cloud data formed in step 2.1.1 according to the display accuracy required by itself, and screens out the effective volume point cloud data that matches the display accuracy; wherein, data calibration specifically refers to decomposing and rearranging the effective volume point cloud data according to the required display accuracy, removing data other than the display accuracy, and retaining only the data required for accuracy, so as to meet the effective volume requirements of different application scenarios. For example, in the filling process of aerospace propellant containers, the effective volume display accuracy that needs to be displayed is 0.02mm, while in the filling process of industrial water tanks, the effective volume display accuracy that needs to be displayed only needs to be 2mm. The display accuracy requires that the amount of point cloud data of the effective volume point cloud data model required for every 2mm increase in liquid level height and every 0.02mm increase in liquid level height is different, and the latter is 100 times the amount of data of the former.

[0042] Step 2.2: Figure 2 As shown, the medium is added or unloaded into the tank container 1, and the liquid level height of the medium is measured in real time by using the liquid level gauge 3 in the tank container 1 and the liquid level height is sent to the liquid level measuring device 4;

[0043] Step 2.3, the liquid level measuring device 4 integrates the received real-time liquid level height into the coordinate system of step 2.1.1, and then takes the cross section where the real-time liquid level height is located as a reference, calculates and displays the real-time liquid level volume according to the effective volume point cloud data below the cross section that matches the display accuracy, and completes the real-time detection of the liquid level volume in the tank container 1.

[0044] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A real-time detection method for liquid level and volume in a tank container, characterized in that: The following steps are involved: Step 1, calculating the effective volume of the tank container (1); Step 1.1, using a laser three-dimensional scanning device (2) to first scan the inner surface of the tank container (1) except for the reinforcement component to obtain first effective volume point cloud data, and then scan the outer surface of the reinforcement component to obtain second effective volume point cloud data, and then send the first effective volume point cloud data and the second effective volume point cloud data to an external data processing unit respectively; Step 1.2, the data processing unit integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system, then connects adjacent points in the coordinate system into lines, and then performs surface reconstruction to form an actual model. The data processing unit calculates the effective volume of the tank container (1) based on the actual model; Step 1.3, determining the error between the effective volume and the theoretical volume of the tank container (1); If the error is less than 0.5%, the first effective volume point cloud data and the second effective volume point cloud data are respectively sent to the liquid level measuring device (4) on the tank container (1), and step 2 is executed; otherwise, the tank container (1) is returned for repair and the process returns to step 1.1; Step 2: Real-time detection of the liquid level and volume in the tank container (1); Step 2.1, the liquid level measuring device (4) integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system to form effective volume point cloud data of the tank container (1); Step 2.2, filling or unloading the medium into the tank container (1), using the liquid level gauge (3) in the tank container (1) to measure the liquid level of the medium in real time and send the liquid level to the liquid level measuring device (4); Step 2.3, the liquid level measuring device (4) integrates the received real-time liquid level height into the coordinate system of step 2.1, and then uses the cross section where the real-time liquid level height is located as a reference, calculates and displays the real-time liquid level volume according to the effective volume point cloud data below the cross section, and completes the real-time detection of the liquid level volume in the tank container (1).

2. The real-time detection method of liquid level volume in a tank container according to claim 1, characterized in that: Step 2.1 specifically includes the following steps: Step 2.1.1, the liquid level measuring device (4) integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system to form initial effective volume point cloud data of the tank container (1); Step 2.1.2: The liquid level measuring device (4) calibrates the initial effective volume point cloud data formed in step 2.1.1 according to the display accuracy required by the liquid level measuring device (4), and selects and obtains effective volume point cloud data that matches the display accuracy.

3. The real-time detection method of liquid level volume in a tank container according to claim 2, characterized in that: Step 2.3 is as follows: The liquid level measuring device (4) integrates the received real-time liquid level height into the coordinate system of step 2.1.1, and then uses the cross section where the real-time liquid level height is located as a reference, calculates and displays the real-time liquid level volume based on the effective volume point cloud data below the cross section that matches the display accuracy, and completes the real-time detection of the liquid level volume in the tank container (1).

4. The real-time detection method of liquid level volume in a tank container according to claim 3, characterized in that: Step 1.2 specifically includes the following steps: Step 1.2.1, the data processing unit integrates the received first effective volume point cloud data and the second effective volume point cloud data into the same coordinate system, then connects adjacent points in the coordinate system into lines, and then performs surface reconstruction, optimizes surface quality, and adds texture mapping to form an actual model; Step 1.2.2, the data processing unit calculates the cylinder volume of the tank container (1), the volume of the two heads and the volume of the reinforcement component in the tank container (1) according to the actual model formed in step 1.2.1, and then calculates the effective volume of the tank container (1) according to the following formula: The effective volume of the tank container (1) = the volume of the cylinder + the volume of the two heads - the volume of the reinforcement assembly.

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