Digital conversion device and method for floater flow sensor
By using a combination of magnetic induction switch array, magnet and microcontroller in the float flowmeter, the problem that existing float flowmeters cannot output digital signals is solved, and the digital conversion and display of flow values is realized, and remote monitoring and data sharing is supported.
Patent Information
- Application Number
- CN202510330691.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-20
- Publication Date
- 2025-06-17
AI Technical Summary
Existing float flowmeters cannot output digital signals, and cannot obtain flow information when measuring opaque media, resulting in measurement errors and remote monitoring cannot be achieved.
The combination of magnetic induction switch array, magnet and microcontroller is adopted to induce the magnetic field signal of the magnet on the float to output the switch status signal to the microcontroller to realize the digital conversion and display of the flow value.
The digital output of the float flowmeter is realized, which can capture flow changes with high sensitivity in low flow velocity and high viscosity fluid measurements, and maintain measurement stability under high flow velocity or high pressure conditions, supporting remote monitoring and data sharing.
Smart Images
Figure CN120160684A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of flow measurement, and particularly relates to a digital conversion device and method for a float flow sensor. Background Art
[0002] Flow measurement is not only a key link in industrial production processes, but also an important part of fields such as energy management, environmental monitoring, and water resource management. Accurate flow measurement can effectively improve production efficiency, reduce energy consumption, ensure the rational use of resources, and thus promote sustainable development.
[0003] Existing flow meters mainly include turbine flow meters, ultrasonic flow meters, float flow meters, optoelectronic flow meters, etc. Among them, turbine flow meters, gear flow meters, and float flow meters all belong to invasive flow meters and are affected by liquid properties. For example, in the flow measurement of high-flow-rate or high-viscosity fluids, gear flow meters are prone to frictional losses, resulting in an increase in system load and, in severe cases, damage to the pumping device; turbine flow meters are very sensitive to the flow state and temperature changes of the fluid and are easily interfered by impurities in the medium, leading to failure.
[0004] Float flow sensors are widely used in various flow measurement occasions due to their simple structure and insensitivity to fluid characteristics. Float flow meters measure flow through the balance principle of the buoyancy and gravity of the float in the fluid, are applicable to various types of fluids, and perform well especially in the measurement of medium and low flow rates and low-viscosity fluids. However, the measurement readings of existing float flow meters are manually read, and the measurement errors vary from person to person, and digital signals of the flow cannot be provided.
[0005] Optoelectronic float flow meters can overcome the drawback that float flow meters cannot output digital signals. A number of groups of transmitting tubes and receiving tubes are installed on the periphery of the measuring cylinder of the float flow meter. When the flow rate changes, the float is in different positions inside the measuring cylinder. By blocking the light and processing the signals, digital signals of the flow are obtained, expanding the application range of the float flow meter. However, when the measured medium is opaque during use, the light transmission path is blocked, and flow information cannot be obtained. Summary of the Invention
[0006] In order to solve at least one of the above technical problems existing in the prior art, the present invention provides a digital conversion device and method for a float flow sensor.
[0007] The present invention is implemented by the following technical solution: A digital conversion device for a float flow sensor, comprising a float flowmeter, a magnet, a counterweight, a magnetic induction switch array, a single-chip microcomputer, and a display terminal; wherein a plurality of magnet mounting holes are reserved on the outer wall of the float of the float flowmeter, and multiple magnet rings are installed at intervals in the corresponding magnet mounting holes on the float and sealed with waterproof glue. The magnet mounting holes are also filled with a counterweight for making the float reach a preset mass; the magnetic induction switch array is fixed to the outer wall of the measuring cylinder of the float flowmeter by a fixture, and the magnetic induction switches on the magnetic induction switch array are arranged in sequence and their positions correspond to the flow scale lines on the measuring cylinder. The signal input port of the single-chip microcomputer is connected to the magnetic induction switch, and the signal output port of the single-chip microcomputer is connected to the display terminal; each magnetic induction switch on the magnetic induction switch array is used to sense the magnetic field signal of the magnet on the float and output a switch state signal to the single-chip microcomputer, and the single-chip microcomputer outputs a corresponding flow value to the display terminal based on the relationship between the switch state signals output by the magnetic induction switches at different positions and the flow rate.
[0008] Preferably, the fixture is a two-piece structure connected and fixed by bolts. Multiple grooves for installing magnetic induction switches are arranged at intervals along the length direction on the inner side of the two-piece structure, and the axial direction of the grooves is arranged along the width direction of the fixture.
[0009] Preferably, the grooves of the two-piece structure can form a stepped through hole. The diameter of the end of the stepped through hole far from the measuring cylinder is small, and this end is used to lead out the leads of the magnetic induction switches, and the rest is used to install the magnetic induction switches. The leads of the magnetic induction switches are respectively connected to the signal input port of the single-chip microcomputer and the power supply module.
[0010] Preferably, the taper of the side wall of the fixture close to the measuring cylinder is the same as the taper of the outer wall of the measuring cylinder, and the two-piece structure is clamped and fixed by fastening bolts at the ears.
[0011] Preferably, the type of the counterweight is gravel.
[0012] Preferably, the number of magnet mounting holes is four, which are distributed in a cross shape along the outer wall of the float, and the number of corresponding magnets is four; the number of grooves and magnetic induction switches are both nine, and nine flow scale values are printed on the outer wall of the measuring cylinder.
[0013] Preferably, the number of magnet mounting holes is three, which are distributed radially along the outer wall of the float, with a central angle of 120°, and the number of corresponding magnets is three; the number of grooves and magnetic induction switches are both seven, and seven flow scale values are printed on the outer wall of the measuring cylinder.
[0014] The present invention also provides a digital conversion method for a float flow sensor, which includes the following steps: Assemble a float flowmeter, a magnet, and a counterweight, and wire a magnetic induction switch array, a single-chip microcomputer, and a display terminal; Connect the assembled float flowmeter to a pipeline, and at the same time fix the fixture equipped with the magnetic induction switch array on the outer wall of the measuring cylinder of the float flowmeter; Turn on the power of the digital conversion device of the float flow sensor. The float of the float flowmeter floats with the flow of the fluid medium and stabilizes at a certain position in the measuring cylinder; The magnetic induction switch corresponding to this position in the magnetic induction switch array senses the magnetic field, and the switch changes from the normally open state to the closed state and outputs a switch state signal to the single-chip microcomputer; The single-chip microcomputer outputs the corresponding flow value to the display terminal based on the relationship between the switch state signals output by the magnetic induction switches at different positions and the flow rate, and the display terminal displays the flow rate of the medium.
[0015] Preferably, the steps of assembling the float flowmeter, the magnet, and the counterweight include:
[0016] Select an existing float flowmeter, take out the original float in the measuring cylinder for measurement and weighing, and make a new float with the same shape as the original float based on the shape parameters of the original float; Process several magnet mounting holes on the side wall of the new float, place the magnets in the magnet mounting holes, and leave one magnet mounting hole unfilled. Fill the pores of the magnet mounting holes with installed magnets by spraying waterproof paint; First install a magnet in the unfilled magnet mounting hole, inject counterweight into it, fill the pores of this magnet mounting hole by spraying waterproof paint, and ensure that the mass of the float at this time is the same as that of the original float.
[0017] Preferably, when the flow rate of the fluid medium increases, the float rises. When the float is between two scale lines, the output flow value is the lower scale value; When the flow rate of the fluid medium decreases, the float descends. When the float is between two scale values, the output is the upper flow scale value.
[0018] Compared with the prior art, the beneficial effects of the present invention are:
[0019] The present invention combines a magnetic induction switch, a magnet, and a float flow sensor with the control method of a single-chip microcomputer to convert a traditional float flowmeter into a flow measurement device with a digital output function. In the measurement of low flow rate and high viscosity fluids, the high sensitivity of the magnetic induction sensor can capture subtle flow changes, and the float flow sensor provides a stable reference measurement value; In the working conditions of high flow rate or large pressure changes, the structural stability of the float flow sensor and its adaptability to fluid characteristics can make up for the possible measurement fluctuations of the magnetic induction sensor. The two complement each other to achieve flow measurement.
[0020] Through the display screen, the device can display the real-time measured flow data in a timely and stable manner and transmit it to an external system through a communication structure. Operators can obtain the flow information at any time through a monitoring terminal in a control room far from the measurement site, timely grasp the dynamic changes of the flow in the production process, realize remote control, data sharing and centralized management, and provide strong support for intelligent production and industrial automation. Brief Description of the Drawings
[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.
[0022] Figure 1 It is a schematic diagram of the overall structure control of the present invention;
[0023] Figure 2 It is a schematic diagram of the structure of the float of the present invention (Embodiment 1);
[0024] Figure 3 It is a schematic diagram of the structure of the float of the present invention (Embodiment 2);
[0025] Figure 4 It is a schematic diagram of the overall structure of the fixture of the present invention;
[0026] Figure 5 It is a schematic diagram of one of the split structures in the fixture of the present invention;
[0027] Figure 6 It is a schematic diagram of the connection of part of the structure of the present invention.
[0028] In the figure: 101 - float; 102 - graduated cylinder; 103 - guide rod; 2 - magnet; 3 - counterweight; 4 - magnetic induction switch array; 5 - single-chip microcomputer; 6 - display terminal; 7 - fixture. Detailed Embodiments
[0029] Combined with the drawings in the embodiments of the present invention, the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other implementation manners obtained by those of ordinary skill in the art without creative efforts belong to the scope protected by the present invention.
[0030] It should be noted that the structures, proportions, sizes, etc. shown in the attached drawings of this specification are only used to cooperate with the content disclosed in the specification for those familiar with this technology to understand and read, and are not used to limit the conditions for the implementation of the present invention. Therefore, they do not have any substantial technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size, without affecting the effects that the present invention can produce and the purposes that can be achieved, should fall within the scope covered by the technical content disclosed in the present invention. It should be noted that in this specification, relational terms such as first and second are only used to distinguish one entity from several other entities, and do not necessarily require or imply any actual relationship or order between these entities.
[0031] Embodiment 1:
[0032] As Figures 1 to 6 shown, a digital conversion device for a float flow sensor includes a float flowmeter, a magnet 2, a counterweight 3, a magnetic induction switch array 4, a single-chip microcomputer 5, and a display terminal 6; wherein a plurality of magnet mounting holes are reserved on the outer wall of the float 101 of the float flowmeter, and multiple magnets 2 are circumferentially and spacedly installed in the corresponding magnet mounting holes on the float 101 and sealed with waterproof glue. The magnet mounting holes are also filled with a counterweight 3 for making the float 101 reach a preset mass, and the type of the counterweight 3 is gravel; the magnetic induction switch array 4 is fixed to the outer wall of the measuring cylinder 102 of the float flowmeter through a clamp 7. The magnetic induction switches on the magnetic induction switch array 4 are arranged in sequence and their positions correspond to the flow scale lines on the measuring cylinder 102. The signal input port of the single-chip microcomputer 5 is connected to the magnetic induction switches, and the signal output port of the single-chip microcomputer 5 is connected to the display terminal 6; each magnetic induction switch on the magnetic induction switch array 4 is used to sense the magnetic field signal of the magnet on the float 101 and output a switch state signal to the single-chip microcomputer 5, and the single-chip microcomputer 5 outputs a corresponding flow value to the display terminal 6 based on the relationship between the switch state signals output by the magnetic induction switches at different positions and the flow rate.
[0033] The measuring cylinder of the traditional float type flow sensor is transparent and has flow scale markings. As a protective shell, it can effectively prevent the internal components from being damaged, and at the same time facilitate observing the position of the float and the fluid flow state. An elongated and rigid guide rod runs through axially inside. The two ends of the guide rod are fixed to the housing of the flow sensor. Its function is to ensure that the float moves only axially in the fluid, avoiding lateral offset or shaking that may affect the measurement accuracy. The float is made of a lightweight and corrosion-resistant plastic material, and its shape is designed to be streamlined for stable movement in the fluid. When fluid flows through the measuring cylinder, the change in the flow rate causes the position of the float to change, and the flow rate value can be read by reading the scale value on the outer wall of the measuring cylinder.
[0034] The digital conversion device of the float flow sensor proposed by the present invention can be quickly installed on the existing float flow sensor. Select an existing float flowmeter, take out the original float in the measuring cylinder 102 for measurement and weighing, and manufacture a new float 101 with the same shape as the original float based on the shape parameters (diameter, aperture, height) of the original float through 3D printing technology; process a number of magnet mounting holes on the side wall of the new float 101, place the magnets 2 in the magnet mounting holes, and leave one magnet mounting hole without installing a magnet. Fill the pores of the magnet mounting holes with installed magnets by spraying waterproof paint; first install a magnet in the magnet mounting hole without installing a magnet, inject a counterweight 3 into it, fill the pores of the magnet mounting hole by spraying waterproof paint, and ensure that the mass of the new float 101 is the same as that of the original float; install the new float 101 on the guide rod 103 inside the measuring cylinder 102. In order to prevent the measuring medium from penetrating into the float and causing a change in the mass of the float, fill the gap between the magnet and the mounting hole by spraying waterproof paint to ensure sealing.
[0035] Flow scale lines and values are printed on the outer wall of the measuring cylinder of the original float type flowmeter. Normally open magnetic induction switches are fixed at the positions corresponding to the scale lines on the outer wall of the measuring cylinder. The number and interval of the normally open magnetic induction switches determine the resolution of the flow measurement. The more normally open magnetic induction switches and the smaller the interval, the higher the resolution. Design and process a special fixture for fixing the normally open magnetic induction switch array on the outer wall of the measuring cylinder of the original float flow sensor.
[0036] In this embodiment, a float flowmeter of 200L / h - 1000L / h is selected. Nine flow scale values are printed on the outer wall of the measuring cylinder, which are 200L / h, 300L / h... 1000L / h respectively. The number of magnet mounting holes is four, which are distributed in a cross shape along the outer wall of the float 101, and the corresponding number of magnets 2 is four; the number of grooves and magnetic induction switches is both nine, and the central positions of the nine grooves are consistent with the scale lines on the outer wall of the measuring cylinder.
[0037] The fixture 7 is a two-piece structure fixed by bolt connection. Multiple grooves for installing magnetic induction switches are arranged at intervals along the length direction on the inner side of the two-piece structure, and the axial direction of the grooves is arranged along the width direction of the fixture 7. The grooves of the two-piece structure can form a stepped through hole. The diameter of the end of the stepped through hole far from the measuring cylinder 102 is small and this end is used to lead out the leads of the magnetic induction switches, and the rest is used to install the magnetic induction switches. The leads of the magnetic induction switches are respectively connected to the signal input ports and power supply modules of the single-chip microcomputer 5. The taper of the side wall of the fixture 7 close to the measuring cylinder 102 is the same as the taper of the outer wall of the measuring cylinder 102, and the two-piece structure is clamped and fixed by the fastening bolts at the ears.
[0038] The present invention also provides a digital conversion method for a float flow sensor, including the following steps:
[0039] Assemble the rotameter, magnet 2 and counterweight 3, and wire the magnetic induction switch array 4, single-chip microcomputer 5 and display terminal 6;
[0040] Connect the assembled rotameter to the pipeline, and at the same time fix the fixture 7 equipped with the magnetic induction switch array 4 on the outer wall of the measuring cylinder 102 of the rotameter;
[0041] Turn on the power of the digital conversion device of the rotameter flow sensor. The float 101 of the rotameter floats with the flow of the fluid medium and stabilizes at a certain position in the measuring cylinder 102;
[0042] The magnetic induction switch corresponding to this position in the magnetic induction switch array 4 senses the magnetic field, and the switch changes from the normally open state to the closed state and outputs a switch state signal (digital signal "1") to the single-chip microcomputer 5;
[0043] The single-chip microcomputer 5 outputs the corresponding flow value to the display terminal 6 based on the relationship between the switch state signals output by the magnetic induction switches at different positions and the flow rate, and the display terminal 6 displays the flow rate of the medium.
[0044] In this embodiment,
[0045] When the flow rate of the fluid to be measured is stable, the float with the magnet suspended at a stable position. The normally open magnetic induction switch installed on the outer wall of the measuring cylinder changes from the off state to the on state after sensing the magnetic field. According to the aforementioned circuit connection, the +5V DC voltage signal will be input to an input port of the single-chip microcomputer. Through the written control program (obtained based on the relationship between the position of the float and the flow rate, and the relationship formula can be derived through experiments), the flow rate value corresponding to the scale position of the float at this time can be calculated and displayed, thereby converting the flow rate value into a digital quantity and providing it for other automation devices to read through different communication protocols. When the flow rate of the fluid medium increases, the float 101 rises. When the float 101 is between two scale lines, the output flow rate value is the lower scale value; when the flow rate of the fluid medium decreases, the float 101 descends. When the float 101 is between two scale values, the output is the upper flow rate scale value.
[0046] Principle of the digital conversion device of the rotameter:
[0047] When the fluid enters the measuring cylinder of the rotameter, the fluid generates an upward buoyancy force on the float. Under the combined action of the buoyancy force and its own gravity, the float rises or falls until it reaches the equilibrium state of buoyancy and gravity. There is a clear numerical relationship between the displacement of the float and the fluid flow rate. The rotameter reads the fluid flow rate value through scale markings. At the same time, the magnet embedded in the float moves synchronously with the float, and the magnetic field intensity and distribution around it change accordingly. The magnets embedded around the float will move with the float, and the magnetic field intensity and distribution around it will also change, thereby triggering the normally open magnetic induction switch to change from the normally open state to the normally closed state, converting the fluid flow rate value represented by the float at the current position into an electrical signal and transmitting it to the single-chip microcomputer. After the single-chip microcomputer processes the signal, it is provided to other devices for reading according to different communication protocols as required.
[0048] Embodiment 2: The difference from Embodiment 1 is that:
[0049] A rotameter with a flow rate range of 100 mL / h - 700 mL / h is selected. Seven flow scale values are printed on the outer wall of the measuring cylinder; the number of magnet mounting holes is three, which are radially distributed along the outer wall of the float 101 with a central angle of 120°, and the corresponding number of magnets 2 is three; the number of grooves and magnetic induction switches is seven.
[0050] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by those skilled in the art within the technical scope disclosed by the present invention should be covered by the protection scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claimed rights.
Claims
1. A float flow sensor digital conversion device, characterized in that: It comprises a float flowmeter, a magnet (2), a counterweight (3), a magnetic induction switch array (4), a single chip computer (5) and a display terminal (6); The outer wall of the float flowmeter is provided with a plurality of magnet mounting holes, a plurality of magnets (2) are circumferentially spaced and mounted in the corresponding magnet mounting holes on the float (101) and sealed by waterproof glue, and a counterweight (3) is injected into the magnet mounting hole for making the float (101) reach a preset mass; a magnetic induction switch array (4) is fixed to the outer wall of a measuring cylinder (102) of the float flowmeter by a clamp (7), the magnetic induction switches on the magnetic induction switch array (4) are arranged in sequence and their positions correspond to the flow scale lines on the measuring cylinder (102), the signal input port of the single chip microcomputer (5) is connected to the magnetic induction switch, and the signal output port of the single chip microcomputer (5) is connected to the display terminal (6); Each magnetic induction switch on the magnetic induction switch array (4) is used to sense the magnetic field signal of the magnet on the float (101) and output a switch state signal to the single chip microcomputer (5). The single chip microcomputer (5) outputs a corresponding flow value to the display terminal (6) based on the relationship between the switch state signal output by the magnetic induction switches at different positions and the flow rate.
2. A float flow sensor digital conversion device according to claim 1, characterized in that: The clamp (7) is a two-piece split structure fixed by bolt connection, and a plurality of grooves for installing magnetic induction switches are arranged at intervals along the length direction of the inner side of the split structure, and the axial direction of the groove is arranged along the width direction of the clamp (7).
3. A float flow sensor digital conversion device according to claim 2, characterized in that: The two split-structure grooves can form a stepped through hole. The stepped through hole has a smaller diameter at one end away from the measuring cylinder (102) and is used to lead out a lead wire of a magnetic induction switch. The remaining portion is used to install the magnetic induction switch. The lead wires of the magnetic induction switch are respectively connected to a signal input port of a single-chip microcomputer (5) and a power module.
4. A float flow sensor digital conversion device according to claim 3, characterized in that: The taper of the side wall of the clamp (7) close to the measuring cylinder (102) is consistent with the taper of the outer wall of the measuring cylinder (102), and the two split structures are clamped and fixed by fastening bolts on the ears.
5. The float flow sensor digital conversion device according to claim 1 is characterized in that: The type of counterweight (3) is gravel.
6. A float flow sensor digital conversion device according to claim 2, characterized in that: There are four magnet mounting holes, which are distributed in a cross shape along the outer wall of the float (101), and the corresponding number of magnets (2) is four; the number of grooves and magnetic induction switches is nine, and nine flow scale values are printed on the outer wall of the measuring cylinder.
7. A float flow sensor digital conversion device according to claim 2, characterized in that: The number of magnet mounting holes is three, which are radially distributed along the outer wall of the float (101) with a central angle of 120°, and the number of corresponding magnets (2) is three; the number of grooves and magnetic induction switches is seven, and the outer wall of the measuring cylinder is printed with seven flow scale values.
8. A float flow sensor digital conversion method, based on the float flow sensor digital conversion device according to any one of claims 1 to 7, characterized in that: The following steps are involved: Assembling a float flow meter, a magnet (2) and a counterweight (3), and connecting a magnetic induction switch array (4), a single chip microcomputer (5) and a display terminal (6); Connect the assembled float flowmeter to the pipeline, and fix the fixture (7) equipped with the magnetic induction switch array (4) to the outer wall of the measuring cylinder (102) of the float flowmeter; The power supply of the float flow sensor digital conversion device is turned on, and the float (101) of the float flow meter floats up along with the flow of the fluid medium and stabilizes at a certain position in the measuring cylinder (102); The magnetic induction switch corresponding to the position in the magnetic induction switch array (4) senses the magnetic field, the switch changes from a normally open state to a closed state, and outputs a switch state signal to the single chip computer (5); The single chip computer (5) outputs a corresponding flow value to a display terminal (6) based on the relationship between the switch state signal output by the magnetic induction switch at different positions and the flow rate, and the display terminal (6) displays the flow rate of the medium.
9. A float flow sensor digital conversion method according to claim 8, characterized in that: The steps of assembling the float flow meter, the magnet (2) and the counterweight (3) include: Select an existing float flowmeter, take out the original float in the measuring cylinder (102) for measurement, weigh it, and make a new float (101) with the same shape based on the shape parameters of the original float; A plurality of magnet mounting holes are processed on the side wall of the new float (101), and the magnets (2) are placed in the magnet mounting holes, and one of the magnet mounting holes is left without a magnet installed, and the gap of the magnet mounting hole where the magnet has been installed is filled by spraying waterproof paint; First, a magnet is installed in a magnet installation hole where no magnet is installed, and a counterweight (3) is injected therein, and the pores of the magnet installation hole are filled by spraying waterproof paint, and the mass of the new float (101) is ensured to be consistent with the mass of the original float; Install the new float (101) on the guide rod (103) inside the measuring cylinder (102).
10. A float flow sensor digital conversion method according to claim 8, characterized in that: When the flow rate of the fluid medium increases, the float (101) rises, and when the float (101) is located between two scale lines, the output flow value is the lower scale value; when the flow rate of the fluid medium decreases, the float (101) falls, and when the float (101) is located between two scale values, the output is the upper flow scale value.