IO-Link intelligent flow sensor

Abstract

The invention provides an IO-Link intelligent flow sensor which comprises a shell, a probe and a circuit part, the shell comprises an upper cover and a lower cover, the probe is connected with the lower cover, the circuit part comprises a flow measuring unit, a signal processing unit and an IO-Link communication unit, the flow measuring unit is arranged in the probe, and the signal processing unit and the IO-Link communication unit are arranged in the shell. Based on the IO-Link communication unit, two-way communication is achieved, the flow signal processed by the signal processing unit can be sent, and an adjusting instruction sent by an upper computer can be received and sent to the signal processing unit. Moreover, the IO-Link communication unit provides a uniform interface, plug and play can be realized with high compatibility, the signal processing unit can calibrate flow signals, and the influence of interference is reduced through the arrangement of the temperature compensation unit, so that the flow precision measured by the signal processing unit is more accurate.

Description

Technical Field

[0001] The present invention relates to the instrument and meter industry, and particularly to an intelligent flow sensor. Background Art

[0002] A flow sensor is a device for measuring the flow rate of a fluid (gas or liquid), and is widely used in fields such as industrial automation, environmental monitoring, medical equipment, and automotive electronics. The types of flow sensors include mechanical flow sensors, differential pressure flow sensors, and thermal flow sensors. The thermal flow sensor detects the heat carried away by the fluid through a heating element and a temperature sensor, and calculates the flow rate.

[0003] In the process of implementing the prior art, the inventors found that:

[0004] Existing flow sensors usually use analog output to transmit signals. This process is prone to problems such as signal attenuation and poor anti-interference ability of the detection data detected by the flow sensor during signal transmission. When using digital signals of communication protocols such as I2C communication protocol, SPI communication protocol, and UART for signal transmission, it is necessary to customize the data format separately, and there are problems such as short one-way communication distance and poor anti-interference ability.

[0005] Based on the above problems, the present application provides a technical solution for a flow sensor with strong anti-interference ability, high compatibility, plug-and-play, and capable of remotely realizing two-way communication to solve the problems of poor anti-interference ability, low compatibility, and only one-way communication in the prior art. Summary of the Invention

[0006] In view of the above-mentioned disadvantages of the prior art, the purpose of the present invention is to provide a technical solution for a flow sensor with strong anti-interference ability, high compatibility, plug-and-play, and capable of remotely realizing two-way communication to solve the problems of poor anti-interference ability, low compatibility, and only one-way communication in the prior art.

[0007] To achieve the above object and other related objects, the present invention provides an IO-Link intelligent flow sensor, including: a housing, a probe, and a circuit part. The housing includes an upper cover and a lower cover. The probe is connected to the lower cover. The circuit part includes a flow measurement unit, a signal processing unit, and an IO-Link communication unit. The flow measurement unit is disposed in the probe, and the signal processing unit and the IO-Link communication unit are disposed in the housing. The signal processing unit is electrically connected to the flow measurement unit and the IO-Link communication unit respectively, and is used to receive the signal transmitted by the flow measurement unit, process it through the signal processing unit, and output the signal processed by the signal processing unit to the host computer through the IO-Link communication unit.

[0008] Preferably, it further includes: the host computer outputs an adjustment instruction to the IO-Link communication unit, and the IO-Link communication unit transmits the adjustment instruction to the signal processing unit, which is used to control and realize the accurate measurement of the flow measurement unit through the signal processing unit.

[0009] Preferably, the signal processing unit includes a flow signal receiving module, a flow signal processing module, and a flow signal flow value control module. The flow signal flow value control module is mainly used to calibrate the flow value.

[0010] Preferably, it further includes a temperature compensation unit disposed in the probe, which is connected to the signal processing unit and is used to perform temperature compensation when calibrating the flow value;

[0011] The temperature compensation unit at least includes a temperature acquisition unit and a vapor chamber for temperature compensation of the flow detection unit.

[0012] Preferably, the flow measurement unit includes a first thermistor, a second thermistor, and a heat source.

[0013] Preferably, the IO-Link communication unit at least includes an energy supply module and an IO-Link interface for signal input or output. The energy supply module supplies energy to the IO-Link communication unit, the signal processing unit connected to the IO-Link communication unit, the flow measurement unit connected to the signal processing unit, and the temperature acquisition unit.

[0014] Preferably, the IO-Link communication unit further includes a fault diagnosis module, which is at least used to diagnose whether faults occur in the flow measurement unit and the signal processing unit.

[0015] Preferably, the housing is further provided with a key unit, which is connected to the signal processing unit and is used to control the signal processing unit through the key unit.

[0016] As described above, an IO-Link intelligent flow sensor provided by the present invention has the following beneficial effects:

[0017] Based on the IO-Link communication unit, two-way communication is realized. It can not only send the flow signal processed by the signal processing unit, but also receive the adjustment instruction sent by the host computer to the signal processing unit. Moreover, the IO-Link communication unit provides a unified interface, which can achieve plug-and-play with relatively high compatibility;

[0018] The calibration of the flow signal in the signal processing unit, through the setting of the temperature compensation unit, reduces the influence of interference, making the flow accuracy measured by the signal processing unit more accurate. Description of the Drawings

[0019] Figure 1It is a schematic structural diagram of an IO-Link intelligent flow sensor;

[0020] Figure 2 It is a schematic process diagram of the circuit part of an intelligent flow sensor;

[0021] Figure 3 It is a schematic process diagram for the flow value control module of the flow signal to calibrate the flow value;

[0022] Figure 4 It is a schematic process diagram of the IO-Link communication unit of an intelligent flow sensor.

[0023] 1. Housing, 11. Upper cover, 12. Lower cover,

[0024] 2. Probe,

[0025] 3. Circuit part,

[0026] 31. Flow measurement unit,

[0027] 32. Signal processing unit, 321. Flow signal receiving module, 322. Flow signal processing module, 323. Flow signal flow value control module,

[0028] 33. IO-Link communication unit, 331. Power supply module, 332. Fault diagnosis module,

[0029] 4. Temperature acquisition unit,

[0030] 5. Button unit. Detailed implementation mode

[0031] The following specific embodiments illustrate the implementation mode of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0032] Please refer to Figures 1 to 4 . It should be noted that the structures, ratios, sizes, etc. shown in the drawings of this specification are only used to cooperate with the content disclosed in the specification for those skilled in the art to understand and read, and are not used to limit the limited conditions for the implementation of the present invention. Therefore, they do not have technical essence. Any modification of the structure, change of the ratio relationship or adjustment of the size, without affecting the effects that the present invention can produce and the purposes that can be achieved, should still fall within the scope that the technical content disclosed by the present invention can cover. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" cited in this specification are only for the convenience of clear narration, and are not used to limit the scope for the implementation of the present invention. The change or adjustment of their relative relationship, without substantial change in the technical content, should also be regarded as the scope for the implementation of the present invention.

[0033] As Figures 1 to 4 shown, the present invention provides an IO-Link intelligent flow sensor, including: a housing 1, a probe 2 and a circuit part. The housing 1 includes an upper cover 11 and a lower cover 12. The probe 2 is connected to the lower cover 12. The circuit part includes a flow measurement unit 31, a signal processing unit 32 and an IO-Link communication unit 33. The flow measurement unit 31 is disposed in the probe 2. The signal processing unit 32 and the IO-Link communication unit 33 are disposed in the housing 1. The signal processing unit 32 is electrically connected to the flow measurement unit 31 and the IO-Link communication unit 33 respectively, and is used to receive the signal transmitted by the flow measurement unit 31, process it through the signal processing unit 32, and output the signal processed by the signal processing unit 32 to the host computer through the IO-Link communication unit 33.

[0034] Specifically, the housing 1 includes an upper cover 11 and a lower cover 12. The upper cover 11 and the lower cover 12 are fixed by interference fit. The probe 2 is connected to the lower cover 12 by interference fit. The probe 2 includes a probe rod and a connecting nut. The connecting nut plays a role of fixing and locking the probe rod during installation.

[0035] Further, the flow measurement unit 31 includes a first thermistor, a second thermistor and a heat source.

[0036] The flow measurement unit 31 is disposed in the probe 2 for measuring the flow rate. This application adopts the thermal flow measurement technology to achieve. Specifically, the heat source causes a local temperature rise in the medium. The increased temperature is detected by the first thermistor. As long as the medium flows through the heat source, it absorbs the heat of the heat source. The second thermistor detects the resulting temperature change for the display of the flow rate, in order to obtain a relatively wide linear range and make the changing medium temperature obtain an accurate measurement result.

[0037] Further, the signal processing unit 32 includes a flow signal receiving module 321, a flow signal processing module 322, and a flow signal flow value control module 323. The flow signal flow value control module 323 is mainly used to calibrate the flow value.

[0038] The signal processing unit 32 is mainly used to process the signal collected by the flow measurement unit 31. Specifically, the flow signal receiving module 321 is mainly used to receive the flow signal. The flow signal processing module 322 is mainly used to filter out all those irregular and interfering signals, leaving only pure and effective flow signals. The processing of the flow signal processing module 322 at least includes signal filtering and signal amplification. The calibration of the flow value by the flow signal flow value control module 323 is mainly used to ensure the accuracy of the flow value. In a preferred embodiment provided by this application, the flow signal flow value control module 323 is equivalent to a microcontroller.

[0039] Further, it further includes a temperature compensation unit disposed in the probe 2, which is connected to the signal processing unit 32 and is used for performing temperature compensation when calibrating the flow value.

[0040] The temperature compensation unit at least includes a temperature acquisition unit 4 and a steam chamber for temperature compensation of the flow detection unit.

[0041] Specifically, the temperature acquisition unit 4 can accurately sense every fluctuation of the fluid temperature and convert these fluctuations into recognizable electrical signals and transmit them to the signal processing unit 32. After the signal processing unit 32 processes it, it further compensates the calibrated flow value of the flow signal flow value control module 323 according to the change of the ambient temperature, effectively eliminating the adverse impact of the ambient temperature fluctuation on the measurement result, thereby improving the measurement accuracy and enabling the entire system to provide accurate and reliable measurement data in different environments. In a preferred embodiment provided in the present application, preferably, the temperature acquisition unit 4 is a temperature detection element, and a steam chamber for temperature compensation of the flow detection unit is provided in the probe 2.

[0042] Further, the IO-Link communication unit 33 at least includes a power supply module 331 and an IO-Link interface for signal input or output. The power supply module 331 supplies power to the IO-Link communication unit 33, the signal processing unit 32 connected to the IO-Link communication unit 33, the flow measurement unit 31 connected to the signal processing unit 32, and the temperature acquisition unit 4.

[0043] The power supply module 331 in the IO-Link communication unit 33 is mainly used to supply electrical energy to the IO-Link communication unit 33. As Figure 3 shown, the power supply module 331 is connected to the IO-Link interface. Of course, functions such as reverse polarity protection and undervoltage lockout can also be provided between the power supply module 331 and the IO-Link interface.

[0044] It should also be noted that a protection circuit can also be provided between the IO-Link communication unit 33 and the upper computer for protection. On the premise that the IO-Link interface of the IO-Link communication unit 33 controls and monitors the flow signal flow value control module 323 of the signal processing unit 32, a wake-up detection function can also be provided to wake up the sleeping system through a specific signal (such as a button, a communication message).

[0045] In addition, the power supply module 331 also supplies power to other modules of the intelligent flow sensor through the IO-Link communication unit 33, such as supplying power to the temperature compensation unit.

[0046] Specifically, the IO-Link interface is easy to integrate with existing industrial control systems. In this application, the IO-Link communication unit 33 communicates with the host computer through the IO-Link interface, transmitting flow data, status information, and fault diagnosis results. The IO-Link communication unit 33 can organize and encapsulate the relevant data of the received flow in a real-time and accurate manner, and transmit it to the host computer continuously through the stable and reliable IO-Link interface in an efficient coding manner. After receiving the flow data, the host computer can conduct in-depth mining and analysis with the help of advanced software algorithms and data analysis tools, so as to achieve comprehensive monitoring and precise control of the fluid medium flow situation in the entire production process. The IO-Link communication unit 33 continuously monitors the working status of the device and transmits it to the host computer in real time. Based on the received status information, the host computer can promptly detect potential problems that may occur in the device, take corresponding preventive measures in advance, and avoid production interruptions or quality fluctuations caused by equipment failures.

[0047] Furthermore, the IO-Link communication unit 33 further includes a fault diagnosis module 332, which is at least used to diagnose whether the flow measurement unit 31 and the signal processing unit 32 have failures.

[0048] Specifically, the transmission of the results of the fault diagnosis module 332 is also an important function of the IO-Link communication unit 33. When the intelligent flow sensor fails, the IO-Link communication module, relying on its powerful fault diagnosis ability, can quickly conduct in-depth analysis of the fault, accurately judge the type, severity, and possible impact range of the fault. It will transmit these detailed fault diagnosis results, together with key information such as the time and location of the fault occurrence, to the host computer through the IO-Link interface. After receiving the fault diagnosis results, the host computer can not only quickly start the emergency plan and take corresponding measures to reduce the impact of the fault on production, but also provide strong data support for subsequent equipment maintenance and repair, helping maintenance personnel locate and solve problems faster, thereby reducing downtime and improving production efficiency. In a preferred embodiment provided in this application, the fault diagnosis module 332 is at least used to diagnose whether the flow measurement unit 31 and the signal processing unit 32 have failures.

[0049] Furthermore, the housing 1 is also provided with a key unit 5, which is connected to the signal processing unit 32 and is used to control the signal processing unit 32 through the key unit 5.

[0050] Specifically, the connection between the key unit 5 and the signal processing unit 32 is mainly used to control the signal processing unit 32 through the key, and through the control of the signal processing unit 32, the accurate measurement of the flow measurement unit 31 is achieved.

[0051] The signal processing unit 32 is electrically connected to the flow measurement unit 31 and the IO-Link communication unit 33 respectively, and is used to receive the signal transmitted by the flow measurement unit 31. After being processed by the signal processing unit 32, the signal processed by the signal processing unit 32 is output to the host computer through the IO-Link communication unit 33.

[0052] It can be understood that the intelligent flow sensor of the present application realizes the transmission of signals through the IO-Link communication unit 33. Compared with the previous analog output and digital signal output, the present application can achieve functions with high compatibility, plug and play, and strong anti-interference ability.

[0053] Furthermore, the host computer outputs an adjustment instruction to the IO-Link communication unit 33, and the IO-Link communication unit 33 transmits the adjustment instruction to the signal processing unit 32, which is used to control the precise measurement of the flow measurement unit 31 through the signal processing unit 32.

[0054] Specifically, the intelligent flow sensor of the present application realizes the function of bidirectional transmission through the IO-Link communication unit 33, that is, the signal processing unit 32 of the sensor can be adjusted by issuing an adjustment instruction from the host computer to achieve the precise measurement of the flow measurement unit 31. Of course, the signal processing unit 32 of the sensor can also be controlled through the button unit 5, and then the precise measurement of the flow measurement unit 31 can be realized.

[0055] The above embodiments are only illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Any person familiar with this technology can modify or change the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the technical field without departing from the spirit and technical idea disclosed by the present invention should still be covered by the claims of the present invention.

Claims

1. An IO-Link intelligent flow sensor, characterized in that, It includes: A housing, a probe and a circuit part. The housing includes an upper cover and a lower cover. The probe is connected to the lower cover. The circuit part includes a flow measurement unit, a signal processing unit and an IO-Link communication unit. The flow measurement unit is arranged inside the probe. The signal processing unit and the IO-Link communication unit are arranged inside the housing. The signal processing unit is electrically connected to the flow measurement unit and the IO-Link communication unit respectively, and is used to receive the signal transmitted by the flow measurement unit, process it through the signal processing unit, and output the signal processed by the signal processing unit to the host computer through the IO-Link communication unit.

2. The intelligent flow sensor according to claim 1, wherein, It also includes: The host computer outputs an adjustment instruction to the IO-Link communication unit, and the IO-Link communication unit transmits the adjustment instruction to the signal processing unit, which is used to control the accurate measurement of the flow measurement unit through the signal processing unit.

3. The intelligent flow sensor according to claim 2, wherein The signal processing unit includes a flow signal receiving module, a flow signal processing module, and a flow signal flow value control module. The flow signal flow value control module is used to calibrate the flow value.

4. The intelligent flow sensor according to claim 3, wherein It also includes a temperature compensation unit arranged inside the probe, which is connected to the signal processing unit and is used to perform temperature compensation when calibrating the flow value. The temperature compensation unit at least includes a temperature acquisition unit and a steam chamber for temperature compensation of the flow detection unit.

5. The intelligent flow sensor according to claim 1, characterized in that, The flow measurement unit includes a first thermistor, a second thermistor, and a heat source.

6. The intelligent flow sensor according to claim 4, characterized in that, The IO-Link communication unit at least includes an energy supply module and an IO-Link interface for signal input or output. The energy supply module supplies energy to the IO-Link communication unit, the signal processing unit connected to the IO-Link communication unit, the flow measurement unit connected to the signal processing unit, and the temperature acquisition unit.

7. The intelligent flow sensor according to claim 6, wherein The IO-Link communication unit also includes a fault diagnosis module, which is at least used to diagnose whether the flow measurement unit and the signal processing unit have faults.

8. The intelligent flow sensor according to claim 1, wherein, The housing is also provided with a key unit, which is connected to the signal processing unit and is used to control the signal processing unit through the key unit.

Images