Intelligent calibration system for density sensors

Abstract

The application discloses an intelligent calibration system of a density sensor, and belongs to the technical field of sensor detection, which comprises a calibration detection frame, a liquid calibration disc is arranged on the calibration detection frame, connecting end covers are arranged above and below the liquid calibration disc, circulating pipelines are connected with the connecting end covers, an eddy current circulating device is arranged in the connecting end cover located at the lower side, is used for simulating liquid flow and conducting liquid wear test, mounting seats are arranged on the two sides of the liquid calibration disc, and gas supply devices and high-frequency vibration devices are respectively arranged in the mounting seats. Through static distance calibration, dynamic eddy current interference, dynamic fluid simulation, wear resistance test and other modules, the actual working conditions of a flue gas desulfurization system are comprehensively simulated, the sound velocity ratio under different paths is measured, compared with the factory calibration value, hardware problems such as probe loosening, mechanical deformation or transducer failure are quickly judged, the complicated separate hardware detection step before traditional calibration is avoided, the process is simplified, and the efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of sensor detection technology, and in particular to an intelligent calibration system for a density sensor. Background Technology

[0002] Ultrasonic density meters are used in flue gas desulfurization systems to monitor the density of media such as limestone slurry and gypsum slurry, directly affecting desulfurization efficiency and equipment operation safety. Ultrasonic density sensors calculate the time difference between upstream and downstream propagation of ultrasonic waves over a fixed distance, eliminating flow velocity interference and accurately measuring sound velocity. Ultrasonic desulfurization density meters are a reliable choice in wet desulfurization systems. However, in actual use, numerous interference factors often exist. Some ultrasonic density meters are frequently subjected to continuous abrasion and erosion from bubbles and particles within the liquid. Therefore, ultrasonic density sensors have certain requirements for the wear resistance of the materials and the anti-interference effect of bubbles. Furthermore, current calibration of ultrasonic density sensors is mainly based on the premise that the product's hardware quality is qualified. This necessitates hardware testing before ultrasonic density sensor calibration, making the testing process very cumbersome. Without hardware testing, the final measurement results will be inaccurate. Based on this, an intelligent calibration system for density sensors is proposed. Summary of the Invention

[0003] The purpose of this invention is to solve the problem that the current calibration of ultrasonic density sensors mainly relies on the hardware quality of the product. This requires hardware testing before the ultrasonic density sensor can be calibrated, which is very cumbersome. If the hardware is not tested, the final result will be inaccurate. Therefore, this invention proposes an intelligent calibration system for density sensors.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A smart calibration system for a density sensor includes a calibration test frame with a liquid calibration disk on the frame. The liquid calibration disk has connecting end covers on both the top and bottom, and the connecting end covers are connected to circulation pipes. A vortex circulation device is installed inside the lower connecting end cover to simulate liquid flow and conduct liquid abrasion tests. Mounting seats are provided on both sides of the liquid calibration disk, and an air supply device and a high-frequency vibration device are respectively installed in the mounting seats.

[0006] The liquid calibration disk consists of a central support ring and rotatably mounted adjustment rings at both ends of the support ring. The support ring is fixedly connected to the mounting base. Calibration kits are respectively mounted on the adjustment rings located opposite each other on both sides of the support ring. A fixed limiting ring is fixedly mounted on the outer wall of the support ring, and a locator is provided on the fixed limiting ring to limit the angle and position of the calibration kits.

[0007] As a preferred embodiment, the calibration kit includes a steering mounting ball disposed on an adjustment mounting ring, the steering mounting ball having an assembly sleeve for mounting a density sensor, the assembly sleeve having a threaded groove adapted to the density sensor.

[0008] As a preferred embodiment, a control valve is provided on the circulation pipeline located below the connecting end cover. The control valve closes the circulation pipeline to ensure that the test liquid is stored in the liquid calibration pan for static testing.

[0009] As a preferred embodiment, the vortex circulation device includes an electric worm gear disk disposed in the connecting end cover located below, the air supply device includes an air pump, the air outlet pipe of the air pump is connected to a bubble ring, and a bubble ring is provided on the inner side wall of the support ring to generate dense bubbles.

[0010] As a preferred embodiment, the positioner includes a fixed-distance port opened on a fixed limiting ring, a positioning adjustment plate slidably disposed in the fixed-distance port, a positioning ring opening opened on the positioning adjustment plate, and a positioning magnetic layer for magnetic attraction of the assembly sleeve disposed in the positioning ring opening;

[0011] The fixed-distance port is used to limit and fix the positioning adjustment plate by fastening bolts.

[0012] As a preferred embodiment, the output end of the high-frequency vibration device is connected to the adjustment mounting ring, which is used to drive the calibration kit located on the adjustment mounting ring to vibrate.

[0013] As a preferred embodiment, the circulation pipeline includes a circulation pipe and a storage tank connected to the circulation pipe, and a circulation pump is installed in the storage tank.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0015] 1. This invention comprehensively simulates the actual working conditions of a flue gas desulfurization system, such as liquid flow, bubble interference, particle wear, and mechanical vibration, through modules such as static distance calibration, dynamic eddy current interference, dynamic fluid simulation, and wear resistance testing, thereby achieving comprehensive verification of sensor performance and improving the reliability of calibration results.

[0016] 2. This invention quickly identifies hardware problems such as probe loosening, mechanical deformation, or transducer failure by measuring the sound velocity ratio (L1 / L2=V1*T2 / V2*T1) under different paths and comparing it with the factory calibration value. This avoids the cumbersome separate hardware testing steps before traditional calibration, simplifies the process, and improves efficiency.

[0017] 3. This invention integrates a high-frequency vibration device, a bubble ring, and an eddy current circulation device, which can quantitatively analyze the impact of vibration, bubbles, and particle wear on sensor accuracy, providing data support for optimizing sensor anti-interference design (such as material wear resistance and bubble suppression algorithms), and enhancing its stability under complex working conditions. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the assembly structure of an intelligent calibration system for a density sensor proposed in this invention;

[0019] Figure 2 This is a three-dimensional structural schematic diagram of an intelligent calibration system for a density sensor proposed in this invention;

[0020] Figure 3 This is a schematic diagram of the liquid calibration disk in an intelligent calibration system for a density sensor proposed in this invention;

[0021] Figure 4 This is a schematic diagram of the structure of an intelligent calibration system for a density sensor proposed in this invention;

[0022] Figure 5 This invention provides a framework for an intelligent calibration system for a density sensor. Figure 1 ;

[0023] Figure 6 This invention provides a framework for an intelligent calibration system for a density sensor. Figure 2 .

[0024] In the diagram: 1. Calibration test frame; 2. Liquid storage tank; 3. Connecting end cover; 4. Mounting base; 5. High-frequency vibration device; 6. Air supply device; 7. Support ring; 8. Adjusting mounting ring; 9. Fixed limit ring; 10. Steering mounting ball; 11. Assembly sleeve; 12. Control valve; 13. Electric worm gear; 14. Bubble ring; 15. Distance port; 16. Positioning adjustment plate; 17. Positioning magnetic layer; 18. Fastening bolt; 19. Circulation pipeline. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0028] Example, refer to Figures 1 to 6 A smart calibration system for a density sensor includes a calibration test frame 1, on which a liquid calibration plate is provided. The liquid calibration plate consists of a central support ring 7 and adjustable mounting rings 8 rotatably disposed at both ends of the support ring 7. The two are rotatably connected, and a sealing ring is provided between them to ensure a sealing effect.

[0029] The liquid calibration pan is equipped with a connecting end cover 3 at both the top and bottom. The connecting end cover 3 is connected to a circulation pipeline. Furthermore, a control valve 12 is installed on the circulation pipeline located below the connecting end cover 3. The control valve 12 closes the circulation pipeline to ensure that the test liquid is stored in the liquid calibration pan for static testing.

[0030] The circulation pipeline includes a circulation pipe 19 and a liquid storage tank 2 connected to the circulation pipe 19. A circulation pump is installed in the liquid storage tank 2. The function of the circulation pump is to circulate the liquid in the liquid storage tank 2 to simulate the state of fluid flow.

[0031] A vortex circulation device is installed inside the lower connecting end cover 3 to simulate liquid flow and conduct liquid wear tests. Furthermore, the vortex circulation device includes an electric worm gear 13 installed inside the lower connecting end cover. When it is necessary to conduct wear resistance tests on the ultrasonic density sensor or investigate the impact of wear on the accuracy of the ultrasonic density sensor, particles can be added to the liquid after the control valve 12 is closed. By opening the electric worm gear 13 installed inside the lower connecting end cover 3, the vortex generated by the electric worm gear 13 will continuously wear the ultrasonic density sensor installed in the assembly sleeve 11, thereby achieving the purpose of the test.

[0032] The liquid calibration pan is equipped with mounting bases 4 on both sides. The mounting bases 4 are respectively equipped with an air supply device 6 and a high-frequency vibration device 5. The high-frequency vibration device 5 generates vibration to investigate the interference effect of vibration on the ultrasonic density sensor. The output end of the high-frequency vibration device 5 is connected to the adjustment mounting ring 8 to drive the calibration kit on the adjustment mounting ring 8 to vibrate. The air supply device 6 includes an air pump. The inner wall of the support ring 7 is provided with a bubble ring 14. The air outlet pipe of the air pump is connected to the bubble ring 14 to generate dense bubbles.

[0033] A large number of bubbles are generated at the path of the ultrasonic density sensor by the gas supply device 6 and the bubble ring 14 to simulate the time-dependent working conditions of the liquid in the flue gas desulfurization system, so as to explore the influence of the bubble liquid on the ultrasonic density sensor under actual use.

[0034] The support ring 7 is fixedly connected to the mounting base 4. Calibration kits are respectively provided on the adjusting mounting rings 8 located opposite each other on both sides of the support ring 7. Further, the calibration kit includes a steering mounting ball 10 provided on the adjusting mounting ring 8. The steering mounting ball 10 is provided with an assembly sleeve 11 for mounting the density sensor. The position of the assembly sleeve 11 can be changed by rotating the adjusting mounting rings 8 on both sides. The assembly sleeve 11 has a threaded groove adapted to the density sensor. The assembly sleeve 11 is designed according to the installation structure of the ultrasonic density sensor to ensure a sealing effect after the ultrasonic density sensor is installed.

[0035] A fixed limiting ring 9 is fixedly installed on the outer wall of the support ring 7. The fixed limiting ring 9 is provided with a positioning device for limiting the angle and position of the calibration kit. The positioning device includes a distance port 15 opened on the fixed limiting ring 9. A positioning adjustment plate 16 is slidably installed in the distance port 15. A positioning ring opening is opened on the positioning adjustment plate 16. A positioning magnetic layer 17 for magnetic attraction of the assembly sleeve 11 is provided in the positioning ring opening. The distance port 15 is used for limiting and fixing the positioning adjustment plate 16 by fastening bolts 18.

[0036] It should be noted that the positioner is designed in advance to ensure that the assembly sleeve 11 is limited to the corresponding angle under the action of the positioning adjustment plate 16, so that the receiving end and the transmitting end of the ultrasonic density sensor can be aligned, thus ensuring the accuracy of the detection results.

[0037] The present invention has the following functions when detecting ultrasonic density sensors: static distance calibration detection, dynamic eddy current interference detection, and dynamic fluid simulation detection.

[0038] Installation preparation: Install the receiving end and transmitting end of the ultrasonic density sensor on the assembly sleeve 11 respectively. Since the assembly sleeve 11 is designed according to the installation of the ultrasonic density sensor, it can achieve effective sealing after the ultrasonic density sensor is threaded and tightened. At this time, the ultrasonic density sensor set on the adjusting mounting ring 8 is in a relative position, and the distance between the two is at its maximum.

[0039] During static distance calibration testing, the test liquid in the storage tank 2 is transported upward through the circulation pipe 19. Under the action of the circulation pump, the liquid is gradually transported to the liquid calibration pan. When the liquid level in the liquid calibration pan meets the test requirements, the circulation pump and control valve 12 are shut off. At this time, the hardware requirements of the ultrasonic density sensor are tested. The position of the assembly sleeve 11 is changed by rotating the adjustment mounting rings 8 set on both sides. The upper and lower staggered adjustment mounting rings 8 will change the distance between the ultrasonic density sensors installed in them when the position of the assembly sleeve 11 is changed. When the angle of the ultrasonic density sensor is adjusted, the angle of the steering mounting ball 10 can be limited by the positioning adjustment plate 16.

[0040] Based on this, the relationship between the propagation time t of ultrasound in a liquid and the fixed probe spacing L is as follows:

[0041] t = L / v;

[0042] Where v is the speed of sound (known or available from a table), by measuring t, we can infer whether L is consistent with the factory calibration value. To ensure the accuracy of the test results, we can compare the measurement results of different paths while changing the path L, as follows:

[0043] Measure the sound velocities V1 and V2 under different paths L1 and L2 in the same liquid, and calculate the theoretical probe spacing ratio:

[0044] L1 / L2 = V1*T2 / V2*T1;

[0045] If the ratio is not equal to the factory calibration value, it indicates that the L value of a certain path is abnormal. At this time, it can be determined that there is a hardware failure in the ultrasonic sensor (loose probe or mechanical deformation, dirt / bubble adhesion or transducer failure).

[0046] After completing the fault detection and calibration of the ultrasonic sensor hardware, the ultrasonic density sensor is moved to the required distance by adjusting the position of the mounting ring 8 for dynamic eddy current interference detection. The circulation pump and control valve 12 are turned on to make the liquid in the liquid calibration pan flow, simulating the flow of liquid in the flue gas desulfurization system. During this process, vibration is generated by the high-frequency vibration device 5 to explore the interference effect of vibration on the ultrasonic density sensor.

[0047] A large number of bubbles can be generated at the path of the ultrasonic density sensor by the gas supply device 6 and the bubble ring 14 to simulate the time working conditions of the liquid in the flue gas desulfurization system, so as to explore the influence of the bubble liquid on the ultrasonic density sensor under actual use. In addition, during the test, the electric worm gear disk 13 set in the lower connecting end cover 3 can be opened simultaneously to generate eddies to increase the interference intensity of the liquid, so as to explore whether the accuracy of the ultrasonic density sensor meets the expected requirements.

[0048] When it is necessary to conduct wear resistance tests on ultrasonic density sensors or investigate the impact of wear on the accuracy of ultrasonic density sensors, particles can be added to the liquid after closing the control valve 12. By opening the electric worm gear 13 set in the lower connecting end cover 3, the eddy current generated by the electric worm gear 13 will continuously wear the ultrasonic density sensor installed in the assembly sleeve 11, thus achieving the purpose of the test.

[0049] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An intelligent calibration system for a density sensor, comprising a calibration testing frame (1), characterized in that, The calibration test rack (1) is provided with a liquid calibration plate. The liquid calibration plate is provided with a connecting end cover (3) above and below. The connecting end cover (3) is connected to a circulation pipeline. The connecting end cover (3) located below is provided with a vortex circulation device for simulating liquid flow and conducting liquid wear tests. The liquid calibration plate is provided with mounting bases (4) on both sides. The mounting bases (4) are respectively provided with an air supply device (6) and a high-frequency vibration device (5). The liquid calibration disk consists of a central support ring (7) and adjustable mounting rings (8) rotatably disposed at both ends of the support ring (7). The support ring (7) is fixedly connected to the mounting base (4). Calibration kits are respectively disposed on the adjustable mounting rings (8) located opposite each other on both sides of the support ring (7). A fixed limiting ring (9) is fixedly disposed on the outer wall of the support ring (7). A locator is disposed on the fixed limiting ring (9) to limit the angle and position of the calibration kit.

2. The intelligent calibration system for a density sensor according to claim 1, characterized in that, The calibration kit includes a steering mounting ball (10) disposed on an adjustment mounting ring (8), the steering mounting ball (10) being provided with an assembly sleeve (11) for mounting a density sensor, the assembly sleeve (11) having a threaded groove adapted to the density sensor.

3. The intelligent calibration system for a density sensor according to claim 1, characterized in that, A control valve (12) is provided on the circulation pipeline located below the connecting end cover (3). The control valve (12) closes the circulation pipeline to ensure that the test liquid is stored in the liquid calibration pan for static testing.

4. The intelligent calibration system for a density sensor according to claim 1, characterized in that, The vortex circulation device includes an electric worm gear disc (13) located in the connecting end cover below, the air supply device (6) includes an air pump, the inner wall of the support ring (7) is provided with a bubble ring (14), and the air outlet pipe of the air pump is connected to the bubble ring (14) to generate dense bubbles.

5. The intelligent calibration system for a density sensor according to claim 1, characterized in that, The positioner includes a fixed distance port (15) opened on a fixed limiting ring (9), a positioning adjustment plate (16) is slidably arranged in the fixed distance port (15), a positioning ring port is opened on the positioning adjustment plate (16), and a positioning magnetic layer (17) for magnetic attraction of the assembly sleeve (11) is arranged in the positioning ring port. The fixed-distance port (15) is used to limit and fix the positioning adjustment plate (16) by fastening bolts (18).

6. The intelligent calibration system for a density sensor according to claim 1, characterized in that, The output end of the high-frequency vibration device (5) is connected to the adjustment mounting ring (8) to drive the calibration kit on the adjustment mounting ring (8) to vibrate.

7. The intelligent calibration system for a density sensor according to claim 1, characterized in that, The circulation pipeline includes a circulation pipe (19) and a storage tank (2) connected to the circulation pipe (19), and a circulation pump is installed in the storage tank (2).

Images