PID photoionization gas sensor module
The PID photoionization gas sensor module, designed with a layered gas path and variable speed fan, solves the problem of improving the response performance of traditional sensors, achieving fast response, accurate detection and low power consumption, and is suitable for petrochemical and emergency monitoring scenarios.
Patent Information
- Application Number
- CN202511761204.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-27
- Publication Date
- 2026-02-24
AI Technical Summary
Existing PID photoionization gas sensors suffer from high costs or poor performance in improving response performance, and cannot simultaneously meet the requirements of miniaturization, intelligence, and high reliability.
It adopts an integrated structure with a layered air path design, variable speed fan and intelligent compensation. By controlling the fan speed, the airflow speed is adjusted according to the change of gas concentration. Combined with sensor components and controller, it can achieve fast response and high-precision detection.
It achieves rapid response, accurate detection, and low power consumption in high-risk scenarios such as petrochemicals and emergency monitoring, reducing maintenance costs and featuring miniaturization, intelligence, and high reliability.
Smart Images
Figure CN121558853A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of intelligent sensor technology, and more specifically, to a PID photoionization gas sensor module. Background Technology
[0002] In the field of industrial safety, leaks of toxic, harmful, flammable, and explosive organic gases pose a significant safety hazard. PID photoionization gas sensors are commonly used to detect such leaks. These sensors have many key performance indicators, including signal-related indicators such as range, resolution, and accuracy; sensor safety indicators such as meeting UL safety requirements, CE certification requirements, or IECEx requirements; and sensor response indicators such as T90 (the time required for the sensor to read from 0 to 90% of the standard gas concentration after calibration) and T10 (the time required for the sensor reading to drop back to 10% of the highest concentration after the standard gas is turned off).
[0003] There are many types of PID gas sensors, but most PID photoionization gas sensors on the market are either bare PID sensors or smart PID sensors. A bare PID sensor typically includes only the necessary UV lamp, signal detection electrodes, drive circuit, simple signal conversion circuit, and a housing and internal structural accessories. A smart PID sensor, in addition to the bare PID sensor, also includes a microcontroller, sensor signal analysis and processing, and AD conversion output functions. Bare PID sensors usually detect raw electrical signal data, and the output is generally an analog voltage or current signal. Users must design their own subsequent application circuits to convert the raw signal into the target signal, increasing the difficulty of use. Smart PID sensors, while processing the signal path, do not improve the sensor's response performance. With industry progress and development, various PID sensors have emerged on the market, but none have effectively improved the response performance of PID sensors. They are either too costly or ineffective, failing to achieve the desired results or meet customer needs. Summary of the Invention
[0004] The purpose of this invention is to provide a PID photoionization gas sensor module that solves the pain point of traditional PID sensors that either sacrifice response to maintain cost or have high cost and low reliability, and features miniaturization, intelligence and high reliability.
[0005] The embodiments of the present invention are implemented as follows: An embodiment of this application provides a PID photoionization gas sensor module, comprising: The mounting housing has a first mounting cavity and a second mounting cavity inside, and an air inlet structure and an air outlet structure on its outer surface. A fan is disposed in the second mounting cavity, and an air inlet channel and an air outlet channel are provided between the first mounting cavity and the second mounting cavity; A sensor assembly is disposed within the first mounting cavity. A first channel is formed between the outer surface of one side of the sensor assembly and the inner surface of one side of the first mounting cavity, and a second channel is formed between the outer surface of the other side of the sensor assembly and the inner surface of the other side of the first mounting cavity. The first channel is connected to the air inlet structure and the air inlet channel, and the second channel is connected to the air outlet structure and the air outlet channel. The sensing surface of the sensor assembly is located within the second channel and is opposite to the air outlet channel. When the fan is in operation, external gas flows sequentially through the air inlet structure, the first channel, the air inlet channel, the second mounting cavity, the air outlet channel, the second channel, and the air outlet structure. The controller, located in the mounting housing, has a set operating mode, including: adjusting the current wind speed of the fan based on the gas concentration information and target concentration collected by the sensor so that the wind speed of the fan meets the target wind speed condition, wherein the target wind speed and the target concentration have a matching relationship.
[0006] In a possible implementation, the set operating mode includes a first operating mode and a second operating mode; the first operating mode is to control the fan to operate in a first mode when the gas concentration does not exceed the target concentration; the second operating mode is to control the fan to operate in a second mode when the gas concentration exceeds the target concentration; wherein the wind speed corresponding to the first mode is lower than that of the second mode. In a possible implementation, in the second operating mode, the response time of the fan is further controlled based on the difference between the gas concentration and the target concentration; wherein the difference is inversely proportional to the response time.
[0007] In a possible implementation, the mounting housing includes: The first housing has the air inlet structure and the air outlet structure on its outer surface; The second housing has the first mounting cavity and the second mounting cavity; the first housing is detachably mounted on one side of the second housing, and the fan is pressed into the second mounting cavity; The third housing is detachably mounted on the other side of the second housing. In a possible implementation, the air inlet structure and the air outlet structure are symmetrically arranged on the outer surface of the first housing, and a crossbar is provided on one side of the first housing. The position of the crossbar is also opposite to the axis of symmetry of the air inlet structure and the air outlet structure. The air inlet structure and the air outlet structure each include a plurality of air holes arranged in a cluster. In a possible implementation, the air inlet channel and the air outlet channel are respectively openings formed in the side wall of the first mounting cavity.
[0008] In a possible implementation, the second mounting cavity has a symmetrical structure and is symmetrically arranged along the fan to balance the inlet and outlet airflow.
[0009] In a possible implementation, the sensor assembly includes a first sensor and a second sensor, the first sensor being located within the first mounting cavity and the second sensor being partially located within the second mounting cavity; the sensing surfaces of both the first and second sensors are opposite to the air outlet channel.
[0010] In a possible implementation, the first signal processing board of the first sensor is provided with a probe structure, which passes through the end of the third housing for connection to an external power supply and signal path; the second signal processing board of the second sensor is provided with a socket for connection to the plug of the fan, and the second signal processing board is electrically connected to the first signal processing board via pins; the first signal processing board provides the power supply and related electrical signals required for the operation of the second signal processing board.
[0011] In a possible implementation, a protective film is also included, which is affixed to the outer surface of the first housing.
[0012] The beneficial effects of the embodiments of the present invention are: Through the integrated design of layered air path, variable speed fan and intelligent compensation, breakthroughs are achieved in four core dimensions: response speed, detection accuracy, power consumption control and maintenance convenience. It is especially suitable for high-risk scenarios such as petrochemical industry and emergency monitoring. It solves the pain point of traditional PID sensors that "either sacrifice response to ensure cost or have high cost and low reliability". It has the characteristics of miniaturization, intelligence and high reliability. Attached Figure Description
[0013] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.
[0014] Figure 1This is an overall cross-sectional view of a PID photoionization gas sensor module according to an embodiment of the present invention; Figure 2 This is a top view of a PID photoionization gas sensor module according to an embodiment of the present invention; Figure 3 This is an exploded view of a PID photoionization gas sensor module according to an embodiment of the present invention; Figure 4 This is a control flowchart of a PID photoionization gas sensor module according to an embodiment of the present invention; Figure 5 This is a cross-sectional view of the second housing of a PID photoionization gas sensor module according to an embodiment of the present invention.
[0015] Icons: 1. Mounting housing; 11. First housing; 12. Second housing; 121. Crossbar; 122. First channel; 123. Second channel; 124. Second mounting cavity; 13. Third housing; 21. Air inlet structure; 22. Air outlet structure; 3. Fan; 41. First sensor; 411. Partition; 412. Probe structure; 413. First signal processing board; 42. Second sensor; 421. Second signal processing board; 5. Bolt; 6. Controller; 7. Protective film. Detailed Implementation
[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0017] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.
[0018] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0019] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. They are only for the convenience of describing this invention and 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, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0020] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," not that the structure must be completely horizontal, but can be slightly tilted.
[0021] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0022] Please refer to Figures 1 to 5 This embodiment provides a PID photoionization gas sensor module, including: a mounting housing 1, a fan 3, a sensor assembly, and a controller 6. The mounting housing 1 has a first mounting cavity and a second mounting cavity 124 inside, and its outer surface is provided with an air inlet structure 21 and an air outlet structure 22. The first mounting cavity is used to mount the sensor assembly, and the second mounting cavity 124 is used to mount the fan 3. The air inlet structure 21 allows external gas to enter, and through the negative pressure provided by the fan 3, the external gas is discharged through the air outlet structure 22, thus completing the airflow circulation. During the airflow process, it can contact the sensing surface of the sensor assembly, thereby detecting some parameter information of the external gas (such as concentration, temperature, humidity, etc.). The fan 3 is located in the second mounting cavity 124. When the fan 3 is working, it can provide negative pressure to achieve airflow circulation. Moreover, by controlling the wind speed of the fan 3, the airflow speed can be adjusted, thereby adjusting some parameters of the external gas. An air inlet channel and an air outlet channel are provided between the first mounting cavity and the second mounting cavity 124 to realize the connection between the two cavities. The sensor assembly, located within the first mounting cavity, includes a first sensor 41 and a second sensor 42. The first sensor 41 is a PID photoionization gas sensor used to detect leaks of toxic, harmful, flammable, and explosive organic gases. A first signal processing board 413 is located at its bottom, connecting the sensor to a backend system to convert raw signals into usable data. The second sensor 42 is a temperature and humidity sensor used to detect the temperature and humidity of the surrounding environment. A second signal processing board 421 is located at its top, enabling signal conversion and also converting fan control signals. A first channel 122 is formed between the outer surface of one side of the sensor assembly and the inner surface of one side of the first mounting cavity, and a second channel 123 is formed between the outer surface of the other side of the sensor assembly and the inner surface of the other side of the first mounting cavity. A partition 411 is provided on the outer surface of the first sensor 41, separating the first channel 122 from the second channel 123. The shapes of the first channel 122 and the second channel 123 depend on the shape of the sensor assembly and the interior of the first mounting cavity. For example, if the first sensor 41 of the sensor assembly is cylindrical and the first mounting cavity is also cylindrical, the cross-sectional shapes of the first channel 122 and the second channel 123 are semi-annular or partially annular. The first channel 122 and the second channel 123 can achieve airflow partitioning. The first channel 122 is connected to the air inlet structure 21 and the air inlet channel, respectively. The second channel 123 is connected to the air outlet structure 22 and the air outlet channel, respectively. The sensing surface of the sensor assembly is located inside the second channel 123 and opposite to the air outlet channel. When the fan 3 is in working condition, the external gas flows sequentially through the air inlet structure 21, the first channel 122, the air inlet channel, the second mounting cavity 124, the air outlet channel, the second channel 123, and the air outlet structure 22, thereby forming a complete airflow cycle. The controller 6 (such as the fan 3 control board) is located in the mounting housing 1 and has a set operating mode, including: adjusting the current wind speed of the fan 3 based on the gas concentration information and target concentration collected by the sensor so that the wind speed of the fan 3 meets the target wind speed condition. The target wind speed and the target concentration have a matching relationship; the higher the target concentration, the higher the target wind speed needs to be set. The disturbance of the fan 3 can accelerate the flow of gas inside the gas channel and simultaneously accelerate gas exchange on the sensor's sensing surface, improving the sensor's response speed. In this way, the sensor can quickly transmit information about high-concentration gas leaks to the user, allowing the user to make the correct response in the shortest possible time and save the lives of on-site personnel.
[0023] Through the integrated design of layered air path, variable speed fan 3, and intelligent compensation, breakthroughs have been achieved in four core dimensions: response speed, detection accuracy, power consumption control, and ease of maintenance. It is especially suitable for high-risk scenarios such as petrochemical industry and emergency monitoring, and solves the pain point of traditional PID sensors that "either sacrifice response to ensure cost or have high cost and low reliability". It features miniaturization, intelligence, and high reliability.
[0024] Furthermore, the set operating modes include a first operating mode and a second operating mode. The first operating mode is that when the gas concentration does not exceed the target concentration, the fan 3 is controlled to operate in a first mode. The second operating mode is that when the gas concentration exceeds the target concentration, the fan 3 is controlled to operate in a second mode. The wind speed corresponding to the first mode is lower than that of the second mode. When the ambient gas concentration is below the low alarm value (target concentration), the gas poses less harm to the human body. The low-speed operation of the FAN and the T90 response time can meet the disposal requirements, and the low power consumption extends the usage time of battery-powered equipment. When the concentration is above the low alarm value, the high-speed operation of the FAN improves the T90 response speed, quickly ensuring personnel safety. Through the graded wind speed design, the drawbacks of traditional sensor-controlled constant-speed fans 3 are avoided. It avoids wasting power due to high-speed operation at low concentrations and delaying risk response due to low-speed operation at high concentrations, achieving adaptable control for low-risk, low-power consumption and high-risk, fast-response scenarios. In the second working mode, the response time of the fan 3 is also controlled according to the difference between the gas concentration and the target concentration. The difference is inversely proportional to the response time. When the difference is smaller, the fan 3 needs to be controlled to quickly reach the preset high level (corresponding to high wind speed) to reduce the response time of the fan 3, so that the sensor can respond quickly.
[0025] In some embodiments, the mounting housing 1 includes a first housing 11, a second housing 12, and a third housing 13. The first housing 11 presses the fan 3 into a second mounting cavity 124, and the third housing 13 is mounted on the other side of the second housing 12. The second housing 12 has the first mounting cavity and the second mounting cavity 124. The first housing 11 is detachably mounted to one side of the second housing 12 by bolts 5, and presses the fan 3 into the second mounting cavity 124. The third housing 13 is detachably mounted to the other side of the second housing 12 by bolts 5. This detachable connection allows for easy replacement of the fan 3 by disconnecting the first housing 11 from the second housing 12, and similarly, disconnection of the third housing 13 from the second housing 12 by calibrating or replacing the sensor assembly. This eliminates the need for a complete module replacement, reducing maintenance costs. The outer surface of the first housing 11 has the air inlet structure 21 and the air outlet structure 22. Furthermore, the second mounting cavity 124 has a symmetrical structure and is symmetrically arranged along the fan 3, which balances the airflow inlet and outlet, promoting airflow circulation. A protective film is attached to the outer surface of the first housing 11. The protective film can be a waterproof and dustproof film. The protective film has pores that allow only gas molecules to pass through, while water or dust cannot pass through. It can achieve both breathability and waterproof and dustproof functions. In some embodiments, the air inlet structure 21 and the air outlet structure 22 are symmetrically arranged on the outer surface of the first housing 11. A crossbar 121 is provided on one side of the first housing 11, and the position of the crossbar 121 is also opposite to the axis of symmetry of the air inlet structure 21 and the air outlet structure 22. The air inlet structure 21 and the air outlet structure 22 each include multiple air holes arranged in a cluster. After the airflow enters from the air inlet structure 21, it can flow evenly to the sensor sensing surface along a symmetrical path, avoiding detection deviation caused by insufficient local airflow. The clustered arrangement of the air hole structures (air inlet structure 21 and air outlet structure 22) can increase the air intake or exhaust area, avoid the problem of insufficient air intake and easy blockage caused by a single air hole, and adapt to the gas exchange requirements when the fan 3 is running at high speed.
[0026] In some embodiments, the air inlet channel and the air outlet channel are respectively openings formed in the side wall of the first mounting cavity. The cavity structure in the air path adopts a circular arc design to reduce air resistance and improve gas exchange speed. The side wall openings directly connect the first mounting cavity and the second mounting cavity 124, thereby reducing air resistance. At the same time, the opening position is close to the sensor sensing surface, so that the airflow driven by the fan 3 can directly act on the sensing surface through the side wall openings, further shortening the T90 / T10 time and improving the response speed.
[0027] In some embodiments, the sensing surfaces of both the first sensor and the second sensor are opposite to the air outlet channel. The first sensor has a probe structure 412, which passes through the end of the third housing 13 for connection to an external power source; the second sensor has a socket for connection to the plug of the fan 3. The second sensor portion is located in the second mounting cavity 124, allowing its sensing surface to directly contact the flowing gas driven by the fan 3 (rather than the gas stagnant inside the housing), resulting in temperature and humidity readings that are closer to the actual working environment of the sensor; simultaneously, the sensing surface is opposite to the air outlet channel, ensuring that the temperature and humidity data are consistent with the environment detected by the first sensor, resulting in a more accurate compensation algorithm and avoiding concentration detection errors caused by temperature and humidity interference.
[0028] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. A PID photoionization gas sensor module, characterized in that, include: The mounting housing has a first mounting cavity and a second mounting cavity inside, and an air inlet structure and an air outlet structure on its outer surface. A fan is disposed in the second mounting cavity, and an air inlet channel and an air outlet channel are provided between the first mounting cavity and the second mounting cavity; A sensor assembly is disposed within the first mounting cavity. A first channel is formed between the outer surface of one side of the sensor assembly and the inner surface of one side of the first mounting cavity, and a second channel is formed between the outer surface of the other side of the sensor assembly and the inner surface of the other side of the first mounting cavity. The first channel is connected to the air inlet structure and the air inlet channel, and the second channel is connected to the air outlet structure and the air outlet channel. The sensing surface of the sensor assembly is located within the second channel and is opposite to the air outlet channel. When the fan is in operation, external gas flows sequentially through the air inlet structure, the first channel, the air inlet channel, the second mounting cavity, the air outlet channel, the second channel, and the air outlet structure. The controller, located in the mounting housing, has a set operating mode, including: adjusting the current wind speed of the fan based on the gas concentration information and target concentration collected by the sensor so that the wind speed of the fan meets the target wind speed condition, wherein the target wind speed and the target concentration have a matching relationship.
2. The PID photoionization gas sensor module according to claim 1, characterized in that, The set working mode includes a first working mode and a second working mode; the first working mode is that when the gas concentration does not exceed the target concentration, the fan is controlled to work in a first mode; the second working mode is that when the gas concentration exceeds the target concentration, the fan is controlled to work in a second mode; wherein, the wind speed corresponding to the first mode is lower than that of the second mode.
3. The PID photoionization gas sensor module according to claim 2, characterized in that, In the second operating mode, the response time of the fan is also controlled according to the difference between the gas concentration and the target concentration; wherein the difference is inversely proportional to the response time.
4. The PID photoionization gas sensor module according to claim 1, characterized in that, The mounting housing includes: The first housing has the air inlet structure and the air outlet structure on its outer surface; The second housing has the first mounting cavity and the second mounting cavity; the first housing is detachably mounted on one side of the second housing, and the fan is pressed into the second mounting cavity; The third housing is detachably mounted on the other side of the second housing.
5. The PID photoionization gas sensor module according to claim 4, characterized in that, The air inlet structure and the air outlet structure are symmetrically arranged on the outer surface of the first housing. A horizontal bar is provided on one side of the first housing, and the position of the horizontal bar is opposite to the axis of symmetry of the air inlet structure and the air outlet structure. The air inlet structure and the air outlet structure each include multiple air holes arranged in a cluster.
6. The PID photoionization gas sensor module according to claim 1, characterized in that, The air inlet channel and the air outlet channel are openings formed on the side wall of the first mounting cavity.
7. The PID photoionization gas sensor module according to claim 1, characterized in that, The second mounting cavity has a symmetrical structure and is symmetrically arranged along the fan to balance the airflow inlet and outlet.
8. The PID photoionization gas sensor module according to claim 4, characterized in that, The sensor assembly includes a first sensor and a second sensor. The first sensor is located in the first mounting cavity, and the second sensor is partially located in the second mounting cavity. The sensing surfaces of both the first sensor and the second sensor are opposite to the air outlet channel.
9. The PID photoionization gas sensor module according to claim 8, characterized in that, The first signal processing board of the first sensor is provided with a probe structure, which passes through the end of the third housing for connection to an external power supply and signal path; the second signal processing board of the second sensor is provided with a socket for connection to the plug of the fan, and the second signal processing board is electrically connected to the first signal processing board via pins; the first signal processing board provides the power supply and related electrical signals required for the operation of the second signal processing board.
10. The PID photoionization gas sensor module according to claim 4, characterized in that, It also includes a protective film, which is affixed to the outer surface of the first housing.