Inspection and calibration method and system

Abstract

The invention relates to the field of sensors, and provides an inspection and calibration method and system.The inspection and calibration system comprises a controller, a water storage circulating device, a lifting device and a plurality of liquid level sensors to be calibrated; the lifting device is controlled to drive the plurality of liquid level sensors to move from an initial station to a position above the liquid level of the water storage circulating device, and sequentially descend to a plurality of preset depths for immersion type sampling, and meanwhile, each liquid level sensor is triggered at each preset depth to collect liquid level data, so that the consistency of sampling conditions and the accuracy of positions are ensured, and the sampling efficiency is improved. According to the invention, non-standardization and errors caused by manual operation are avoided, the precision of inspection and calibration is improved, then multiple liquid level sensors synchronously complete multi-point sampling and autonomous inspection, parallel processing and efficient detection are realized, the defects of dependence on manual operation, low efficiency and only single calibration in the prior art are overcome, and the accuracy of inspection and calibration is improved. And the overall efficiency and reliability of the inspection and calibration of the liquid level sensor are effectively improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sensors, in particular to a verification and calibration method and system. BACKGROUND

[0002] Liquid level sensors are widely used in many fields such as energy, chemical industry, hydrology, industry and automobile, and the market has increasingly high requirements for their precision, reliability and production efficiency.

[0003] At present, the verification and calibration of liquid level sensors usually rely on manual operation of special equipment composed of water storage devices, water supply and drainage systems, and high-precision measurement systems. The existing technology mainly has the following shortcomings: first, manual operation is low in efficiency, and only one liquid level sensor can be verified and calibrated at a time, further limiting the efficiency of verification and calibration; second, the calibration process highly depends on manual operation, which is easy to introduce human error due to inconsistent or non-standard operation, and it is difficult to ensure the uniformity and high precision of the calibration results.

[0004] Therefore, the existing verification and calibration method of liquid level sensors has obvious limitations in efficiency and precision. SUMMARY

[0005] The purpose of the embodiments of the present application is to provide a verification and calibration method and system to improve the above problems.

[0006] In order to achieve the above purpose, the technical solutions adopted by the embodiments of the present application are as follows: In a first aspect, the present application provides a verification and calibration method applied to a verification and calibration system, the verification and calibration system comprising a controller, a water storage and circulation device, a lifting device and a plurality of liquid level sensors to be calibrated, the controller being connected with the water storage and circulation device, the lifting device and each of the liquid level sensors; the water storage and circulation device is used to provide a calibration environment with constant liquid level; the lifting device is used to carry the plurality of liquid level sensors to be calibrated: The verification and calibration method comprises: The controller responds to a start verification instruction to control the lifting device to move the plurality of liquid level sensors carried thereby from an initial station to above the liquid surface of the water storage and circulation device, and sequentially descend to a plurality of preset depths for immersion sampling; The controller triggers each of the liquid level sensors to collect corresponding liquid level data at each of the preset depths; Each of the liquid level sensors verifies whether it is qualified according to the liquid level data collected at each of the preset depths, obtains a verification result and reports it to the controller.

[0007] Optionally, the verification and calibration method further comprises: If the inspection result is qualified, each of the liquid level sensors generates a calibration model based on all the liquid level data and the plurality of preset depths. The calibration model is used to calibrate the measurement value of the liquid level sensor after it leaves the factory.

[0008] Optionally, the testing and calibration method further includes: After receiving the inspection results reported by each of the liquid level sensors, the controller controls the lifting device to rise to a preset safe position and then return to the initial working position.

[0009] Optionally, the step of each liquid level sensor verifying its own qualification based on the liquid level data it collects at each preset depth includes: Sequentially determine whether the liquid level data collected at each preset depth is within the corresponding preset depth range; If any of the liquid level data exceeds the corresponding preset depth range, the liquid level sensor is deemed unqualified. If each of the liquid level data points is within the corresponding preset depth range, then the liquid level sensor is deemed qualified.

[0010] Optionally, the testing and calibration method further includes: The controller responds to the start test command and determines whether the liquid type required for this test and calibration task is consistent with the liquid type required for the previous test and calibration task. If there is a discrepancy, the user is prompted to replace the liquid and the inspection and calibration process is paused until a confirmation signal indicating that the liquid replacement has been completed is received. Then, the step of controlling the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then descending to multiple preset depths in sequence for immersion sampling is executed. If they match, then the step of controlling the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then sequentially descending to multiple preset depths for immersion sampling is executed.

[0011] Optionally, the water storage and circulation device includes a first water tank, a second water tank, a circulating water pump, a water pump control device, and a circulating water path. The water pump control device is connected to both the controller and the circulating water pump. The circulating water path is located between the first water tank and the second water tank, and the circulating water pump is connected to the circulating water path. The first water tank is provided with an overflow port. When the liquid level in the first water tank exceeds a preset height, excess liquid flows into the second water tank through the overflow port. The testing and calibration method further includes: After receiving the test results reported by each of the liquid level sensors, the controller sends a command to the water pump control device to end the operation. Upon receiving the end-of-operation command, the pump control device activates the circulating water pump to return the liquid in the second water tank to the first water tank via the circulating water path.

[0012] Secondly, embodiments of this application provide an inspection and calibration system, which includes a controller, a water storage and circulation device, a lifting device, and multiple liquid level sensors to be calibrated. The controller is connected to the water storage and circulation device, the lifting device, and each of the liquid level sensors. The water storage and circulation device is used to provide a calibration environment with a constant liquid level; the lifting device is used to carry the multiple liquid level sensors to be calibrated. The controller is used to respond to the start inspection command, control the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then descend to multiple preset depths in sequence for immersion sampling; The controller is also configured to trigger each liquid level sensor to collect corresponding liquid level data at each preset depth; Each of the liquid level sensors is used to check whether it is qualified based on the liquid level data it collects at each preset depth, obtain the check result and report it to the controller.

[0013] Optionally, the water storage and circulation device includes a first water tank, a second water tank, a circulating water pump, a water pump control device, and a circulating water path. The water pump control device is connected to the controller and the circulating water pump. The circulating water path is located between the first water tank and the second water tank. The circulating water pump is connected to the circulating water path. The first water tank is equipped with an overflow port. When the liquid level in the first water tank exceeds a preset height, the excess liquid flows into the second water tank through the overflow port. The controller is also configured to send a termination command to the pump control device after receiving the test results reported by each of the liquid level sensors. The water pump control device is used to start the circulating water pump after receiving the end-of-operation instruction, so as to send the liquid in the second water tank back to the first water tank through the circulating water circuit.

[0014] Optionally, the water storage and circulation device further includes a movable base installed at the bottom of the first water tank; When the controller detects that the liquid type required for the current inspection and calibration task is inconsistent with the liquid type required for the previous inspection and calibration task, and prompts the user to change the liquid, the user replaces the first water tank entirely using the movable base.

[0015] Optionally, the lifting device includes a support frame, a suspended basket, and a lifting and rotating control mechanism, wherein the lifting and rotating control mechanism is connected to the controller; The bracket is vertically fixed, and the lifting and rotating control device is slidably mounted on the bracket to drive the basket to lift vertically along the bracket and rotate around the vertical axis to a specified angle. The basket is fixed to the lower end of the lifting and rotating control mechanism and is used to simultaneously fix multiple liquid level sensors to be calibrated. The basket adopts a hollow structure to ensure that each liquid level sensor is in full contact with the liquid in the water storage and circulation device without affecting the stability of the liquid level.

[0016] Compared to existing technologies, the present application provides a testing and calibration method and system. The testing and calibration system includes a controller, a water circulation device, a lifting device, and multiple liquid level sensors to be calibrated. The water circulation device provides a calibration environment with a constant liquid level. The lifting device carries multiple liquid level sensors to be calibrated. The controller coordinates the operation of the water circulation device, the lifting device, and the multiple liquid level sensors to be calibrated. During the calibration process, after the controller responds to the start testing command, it controls the lifting device to move multiple liquid level sensors from their initial positions to above the liquid surface of the water circulation device, and then sequentially descends to multiple preset depths for immersion sampling. Simultaneously, at each preset depth, each liquid level sensor is triggered to collect liquid level data, ensuring the consistency of sampling conditions and the accuracy of the position, avoiding the irregularities and errors caused by manual operation, and improving the accuracy of testing and calibration. Subsequently, multiple liquid level sensors simultaneously complete multi-point sampling and autonomous testing, realizing parallel processing and efficient detection. This overcomes the shortcomings of existing technologies that rely on manual operation, are inefficient, and can only calibrate one sensor at a time, effectively improving the overall efficiency and reliability of liquid level sensor testing and calibration. Attached Figure Description

[0017] Figure 1 The diagram shows a block illustration of an inspection and calibration system provided in an embodiment of this application. Figure 1 .

[0018] Figure 2 This application provides a schematic flowchart of an inspection and calibration method according to an embodiment. Figure 1 .

[0019] Figure 3 This application provides a schematic flowchart of an inspection and calibration method according to an embodiment. Figure 2 .

[0020] Figure 4 This application provides a schematic flowchart of an inspection and calibration method according to an embodiment. Figure 3 .

[0021] Icons: 100-Inspection and calibration system; 110-Water storage and circulation device; 111-First water tank; 112-Second water tank; 113-Circulating water pump; 114-Water pump control device; 115-Circulating water path; 116-Overflow outlet; 117-Moving base; 118-Drain outlet; 120-Lifting device; 121-Bracket; 122-Lifting and rotating control mechanism; 123-Basket; 130-Controller; 140-Level sensor. Detailed Implementation

[0022] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0023] Please refer to Figure 1 This application provides an inspection and calibration system 100, which includes a water storage and circulation device 110, a lifting device 120, a controller, and a plurality of liquid level sensors 140 to be calibrated. The controller 130 is connected to the water storage and circulation device 110, the lifting device 120, and each liquid level sensor 140, respectively, and the connection can be wired or wireless.

[0024] The water storage and circulation device 110 is used to provide a calibration environment with a constant liquid level. That is, the water storage and circulation device 110 can hold a specified type of calibration liquid (e.g., tap water, alcohol, or other customer-customized liquids) and maintain a constant liquid level height through an internal liquid level control mechanism to ensure that the reference conditions are consistent for each calibration.

[0025] The lifting device 120 is used to carry multiple liquid level sensors 140 to be calibrated and to perform precise spatial positioning actions.

[0026] The controller 130 is the control core of the inspection and calibration system 100, used to run a fully automatic inspection and calibration program to complete the inspection and calibration of multiple (e.g., 30) level sensors 140 at one time.

[0027] Optionally, when the operator starts the inspection and calibration procedure, the controller 130 responds to the start inspection command and sends a start operation command to the lifting device 120. Driven by the start operation command, the lifting device 120 moves the multiple liquid level sensors 140 it carries from the initial position to above the liquid surface of the water storage and circulation device 110, and then descends to multiple preset depths (e.g., 0 meters, 1 meter, 2 meters, 3 meters, etc.) for immersion sampling.

[0028] The controller 130 is also used to send a control signal to each liquid level sensor at each preset depth to trigger each liquid level sensor to collect the corresponding liquid level data.

[0029] Each liquid level sensor 140 is used to check whether it is qualified based on the liquid level data collected at each preset depth, obtain the inspection result and report it to the controller 130.

[0030] Please refer to this again. Figure 1 The water storage and circulation device 110 includes a first water tank 111, a second water tank 112, a circulating water pump 113, a water pump control device 114, and a circulating water path 115. The water pump control device 114 is connected to the controller 130 and the circulating water pump 113. The circulating water path 115 is located between the first water tank 111 and the second water tank 112. The circulating water pump 113 is connected to the circulating water path 115.

[0031] The first water tank 111 is provided with an overflow port 116. When the liquid level in the first water tank 111 exceeds a preset height, the excess liquid flows into the second water tank 112 through the overflow port 116. For example, when the lifting device 120 lowers the multiple liquid level sensors 140 it carries to the liquid immersed in the first water tank 111, the liquid level in the first water tank 111 may exceed the preset height, and the excess liquid flows into the second water tank 112 through the overflow port 116.

[0032] Optionally, the preset height can be the height of the overflow port 116 from the bottom of the first water tank 111. If the overflow port 116 is above this height, excess liquid will flow into the second water tank 112 through the overflow port 116. For example, if the overflow port 116 is located at a height of 3.2 meters above the first water tank 111, then the preset height is 3.2 meters.

[0033] Meanwhile, the preset height is also the constant liquid level required for the calibration environment during the inspection and calibration task. Before the operation begins, the specified liquid is manually added to the first water tank 111 until the liquid overflows and flows into the second water tank 112 through the overflow port 116. At this time, the liquid in the first water tank 111 reaches the preset height (for example, 3.2 meters), which is convenient for subsequent operations.

[0034] The controller 130 is also used to issue a stop operation command to the pump control device 114 after receiving the inspection results reported by each level sensor 140.

[0035] The water pump control device 114 is used to start the circulating water pump 113 after receiving the end-of-work instruction, so as to send the liquid in the second water tank 112 back to the first water tank 111 through the circulating water path 115, thereby ensuring that the liquid level in the first water tank 111 is constant.

[0036] like Figure 1As shown, the water storage and circulation device 110 also includes a movable base 117 installed at the bottom of the first water tank 111. When it is necessary to replace the liquid in the first water tank 111, the user can replace the first water tank 111 as a whole through the movable base 117.

[0037] For example, when a new inspection and calibration task requires updating the liquid, or when the controller 130 detects that the type of liquid required for the current inspection and calibration task is inconsistent with the type of liquid required for the previous inspection and calibration task, and prompts the user to change the liquid, the user can replace the first water tank 111 entirely by moving the base 117.

[0038] Meanwhile, the bottom of the first water tank 111 is provided with a drain outlet 118, which is used to drain the residual liquid in the first water tank 111 after the current inspection and calibration operation is completed.

[0039] In the existing technology, the device used for testing and calibrating liquid level sensors is usually an integrated design, which is often difficult to expand after it is built. For example, changing the liquid requires cleaning the entire water storage device and water supply and drainage system, which is very cumbersome and increases costs.

[0040] The inspection and calibration system 100 provided in this application embodiment, by installing a movable base 117 at the bottom of the first water tank 111, designs the water storage and circulation device 110 as an independent unit that can be moved and replaced as a whole. When it is necessary to change the type of liquid, the user can replace the first water tank 111 as a whole through the movable base 117, that is, remove the current first water tank and move in an empty first water tank that has been cleaned and dried, and add liquid that meets the requirements of this inspection and calibration task, thereby quickly completing the liquid replacement, avoiding cross-contamination problems caused by incomplete cleaning, and improving the flexibility and efficiency of operation.

[0041] Meanwhile, for the first water tank where the liquid does not meet the requirements, the liquid is first drained through the drain outlet, and then the tank is cleaned and dried, making the operation simple.

[0042] The lifting device 120 includes a support 121, a lifting and rotation control mechanism 122, and a basket 123. The lifting and rotation control mechanism 122 is connected to a controller 130. When the operator starts the inspection and calibration procedure, the controller 130 responds to the start inspection command by issuing a start operation command to the lifting and rotation control mechanism 122; and after receiving the inspection results reported by each liquid level sensor 140, the controller 130 issues a stop operation command to the lifting and rotation control mechanism 122.

[0043] The bracket 121 is vertically fixed, and the lifting and rotating control mechanism 122 is slidably installed on the bracket 121 to drive the suspended basket 123 to lift vertically along the bracket 121 and rotate around the vertical axis to a specified angle.

[0044] The basket 123 is fixed to the lower end of the lifting and rotating control mechanism and is used to simultaneously fix multiple liquid level sensors 140 to be calibrated.

[0045] Optionally, the height of the bracket 121 can be flexibly set as needed, as long as it is ensured that when the lifting and rotating control mechanism 122 is at the top of the bracket 121, the liquid level sensor 140 in the basket 123 is at a set height (e.g., 0.3 meters) above the liquid level in the first water tank 111.

[0046] Optionally, the basket 123 adopts a hollow structure so that each liquid level sensor 140 can fully contact the liquid in the water storage and circulation device 110 without affecting the stability of the liquid level.

[0047] Optionally, the bottom of the basket 123 is provided with a sensor base for simultaneously mounting multiple (e.g., 30) sensors, while also supporting quick clamping of different types of sensors.

[0048] The lifting and rotating control mechanism 122 is used to move the basket from the initial position to above the liquid surface of the water storage and circulation device 110 when it receives the start operation command issued by the controller 130, and then descend to multiple preset depths for immersion sampling; and when it receives the end operation command issued by the controller 130, it moves the basket 123 up to a preset safe position and then returns to the initial position.

[0049] In addition, the inspection and calibration system 100 provided in this application embodiment may also include a water supply pipeline and a water tap, used to fill water into the first water tank 111 before the start of the operation when the liquid required for this inspection task is clean water.

[0050] Optionally, the controller 130 can be a hardware device with automation control and data processing capabilities, such as an industrial computer, a programmable logic controller, a host computer system, an embedded control system, or an industrial panel PC.

[0051] Optionally, the liquid level sensor 140 may include a processing unit, a communication module, a sampling module, and a storage module. The processing unit is responsible for coordinating and managing the operation of each module; the sampling module collects liquid level signals from the current environment and converts them into digital liquid level data for the processing unit; the storage module stores historical liquid level data, calibration parameters, and error compensation curves; the communication module supports bidirectional communication with the controller 130, and can receive control signals from the controller 130 and report its own inspection results and operating status.

[0052] The following is a test and calibration method applied to the above-mentioned test and calibration system 100.

[0053] Please refer to Figure 2 , Figure 2A schematic flowchart of an embodiment of the present application is shown. The inspection and calibration method may include the following steps: S101, the controller responds to the start inspection command and controls the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage circulation device, and then descends to multiple preset depths in sequence for immersion sampling. S102, at each preset depth, the controller triggers each liquid level sensor to collect the corresponding liquid level data; S103, each liquid level sensor checks whether it is qualified based on the liquid level data collected at each preset depth, obtains the inspection result and reports it to the controller.

[0054] In step S101, after the operator initiates the inspection and calibration procedure, the controller responds to the start inspection command, starts the calibration process, and sends a start operation command to the lifting device, causing the lifting device to smoothly move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device. Optionally, the initial position is a non-working position used for installing and removing the liquid level sensors to avoid interference from the liquid environment during sampling.

[0055] The lifting device performs spatial positioning actions according to the instructions issued by the controller. After reaching above the liquid surface, the controller further controls the lifting device to sequentially lower multiple liquid level sensors to multiple preset depths (e.g., 0 meters, 1 meter, 2 meters, 3 meters, etc.). Each preset depth corresponds to different static pressure conditions, simulating different liquid level scenarios in actual use. During this process, the water circulation device maintains a constant liquid level, achieving dynamic liquid balance through the overflow port and circulating water pump, providing a stable and reliable liquid level reference environment for the calibration process, and effectively eliminating measurement deviations caused by liquid level fluctuations.

[0056] In step S102, whenever multiple liquid level sensors reach a certain preset depth and remain stable, the controller triggers a data acquisition action and sends a control signal to each liquid level sensor, so that each liquid level sensor acquires the corresponding liquid level data at its actual depth. During this process, each liquid level sensor independently completes its own data acquisition and preliminary analysis.

[0057] In step S103, after the acquisition is completed, the liquid level sensor checks its own qualification based on the liquid level data collected at each preset depth, obtains the inspection result and reports it to the controller. For example, the liquid level sensor compares the liquid level data collected at multiple preset depths with the corresponding preset depth ranges stored in advance in sequence to determine whether there is a situation where the preset depth range is exceeded. If the liquid level data at each preset depth is within the preset depth range, it is determined to be qualified; otherwise, it is determined to be unqualified. In this way, by each liquid level sensor locally checking its own qualification, the data processing burden of the controller is reduced, and the response speed and reliability of the overall system are improved.

[0058] In a possible implementation manner, taking any liquid level sensor as an example, the process in step S103 where each liquid level sensor checks its own qualification based on the liquid level data collected at each preset depth may include: Sequentially determine whether the liquid level data collected at each preset depth is within the corresponding preset depth range; If any liquid level data exceeds the corresponding preset depth range, it is determined that the liquid level sensor is unqualified; If each liquid level data is within the corresponding preset depth range, it is determined that the liquid level sensor is qualified.

[0059] For example, the processing unit of the liquid level sensor reads the liquid level data d0, d1, d2, d3 collected by the sampling module at 0 m, 1 m, 2 m, and 3 m respectively. Then, it sequentially determines whether d0 ≤ 0.1, 0.9 ≤ d1 ≤ 1.1, 1.9 ≤ d2 ≤ 2.1, and 2.9 ≤ d3 ≤ 3.1 are satisfied. Only when all the above 4 items are satisfied is it determined that the liquid level sensor is qualified; otherwise, it is determined that the liquid level sensor is unqualified.

[0060] After each liquid level sensor completes the inspection of its own qualification, it uploads the generated inspection result to the controller. Optionally, the inspection result may at least include the liquid level data at each preset depth and the inspection result (qualified / unqualified). After the controller receives the inspection results reported by all liquid level sensors, it can further summarize them to form a quality inspection report for the operator to consult or import into the quality management system.

[0061] In this embodiment, through the controller to uniformly coordinate the mechanical movement and data acquisition timing, combined with the stable liquid level environment provided by the water storage circulation device and the precise space control ability of the lifting device, parallel calibration of multiple liquid level sensors in the same system is achieved. The entire process requires no manual intervention, avoiding the error risk caused by non-standard manual operations, improving the consistency and accuracy of calibration. At the same time, since multiple liquid level sensors can be carried at one time for continuous depth sampling, the operation time is greatly shortened, and the overall operation efficiency is improved.

[0062] In practical applications of liquid level sensors, their measurement accuracy depends not only on the pre-shipment inspection and calibration process but also on their ability to dynamically correct measurement data during subsequent use. Traditional calibration methods typically only determine the pass / fail status of a single point or a limited number of points, failing to provide continuous support for the long-term stability of the sensor under complex operating conditions. Therefore, it is necessary to further develop an adaptive data model based on successful inspection to improve the measurement reliability of the liquid level sensor throughout its entire lifecycle.

[0063] Therefore, in Figure 2 Based on this, please refer to Figure 3 The testing and calibration method provided in this application embodiment also includes step S104.

[0064] S104, if the inspection result of each liquid level sensor is qualified, a calibration model is generated based on all liquid level data and multiple preset depths. The calibration model is used to calibrate the measurement value of the liquid level sensor after leaving the factory.

[0065] In this embodiment, taking any liquid level sensor with a qualified test result as an example, a mathematical expression can be fitted based on all liquid level data and multiple preset depths to describe its unique nonlinear error characteristics. This mathematical expression is the calibration model. Optionally, the calibration model can be implemented using univariate linear regression, polynomial fitting, or other algorithms suitable for the output characteristics of liquid level sensors, without any limitations.

[0066] Optionally, the generated calibration model is stored in the storage module of the liquid level sensor as a basis for compensating real-time measurement values ​​during subsequent use. When the liquid level sensor collects the current liquid level value in the application scenario, its processing unit calls the calibration model to transform the original sampling result and outputs the compensated calibration value, thereby effectively reducing the impact of systematic deviations and improving the adaptability of the liquid level sensor in complex environments and its long-term measurement consistency.

[0067] After completing the inspection and calibration of the liquid level sensors, it is necessary to ensure that all liquid level sensors are safely removed from the liquid environment and accurately reset to their initial positions for easy disassembly or replacement. If the lifting device moves horizontally directly without fully lifting, the liquid level sensor may collide with the water storage and circulation device, causing equipment damage or contamination of the measuring components, which in turn affects the calibration accuracy and operational safety of subsequent batches.

[0068] Therefore, please refer to again Figure 3 The testing and calibration method provided in this application embodiment also includes step S105.

[0069] S105: After receiving the inspection results reported by each liquid level sensor, the controller controls the lifting device to rise to the preset safe position and then return to the initial position.

[0070] In this embodiment, after receiving the inspection results reported by each liquid level sensor, the controller determines that the current inspection and calibration phase has ended, issues a termination command to the lifting device, and controls the lifting device to move the multiple liquid level sensors it carries vertically upwards until a preset safe position is reached. Optionally, the safe position can be a position above the liquid surface of the water storage and circulation device at a certain distance, ensuring that all liquid level sensors are completely detached from the liquid and have no physical contact with the water storage and circulation device, for example, 3.3 meters.

[0071] Based on this, the controller further controls the lifting device to move multiple liquid level sensors from a safe position back to the initial position. The initial position is a non-immersion operating area, usually located on the side away from the water storage and circulation device, and is dedicated to installing a new batch of sensors or removing liquid level sensors that have completed inspection and calibration.

[0072] For example, after receiving the start inspection command, the controller sends a start operation command to the lifting and rotating mechanism. The lifting and rotating mechanism rises 3.5 meters and turns 90 degrees to the left. The basket moves from the initial position to a position 0.3 meters above the liquid surface of the first water tank. The controller triggers each liquid level sensor to collect and save the 0-meter liquid level data. Then, the controller sends a control command to the lifting and rotating mechanism, controlling the lifting and rotating mechanism to descend 1.3 meters, and the basket descends to 1 meter below the liquid surface of the first water tank. The controller then triggers each liquid level sensor to collect and save the 1-meter liquid level data. The controller continues to send control commands to the lifting and rotating mechanism, controlling the lifting and rotating mechanism to descend 1 meter, and the basket descends to a position 2 meters below the liquid surface of the first water tank. The controller then triggers each liquid level sensor to collect and save the liquid level data at a distance of 2 meters. The controller sends another control command to the lifting and rotating mechanism, controlling the lifting and rotating mechanism to descend 1 meter. The basket descends to a position 3 meters below the liquid surface of the first water tank. The controller then triggers each liquid level sensor to collect and save the liquid level data at a distance of 3 meters. Each liquid level sensor checks its own compliance based on the liquid level data collected at 0 meters, 1 meter, 2 meters, and 3 meters, obtains the inspection results, and reports them to the controller. After receiving the inspection results reported by each liquid level sensor, the controller first controls the lifting and rotating mechanism to rise 3.3 meters, so that the basket returns to the top. Then, it controls the lifting and rotating mechanism to turn 90 degrees to the right and descend 3.5 meters, so that the basket returns to the initial position. Finally, the controller displays the inspection results of each liquid level sensor.

[0073] In practice, level sensor calibration may involve different application scenarios with different media. For example, it may require the use of tap water, alcohol, or other customer-specified liquids for testing and calibration to match the actual operating conditions. In such cases, if the liquid type is not effectively verified and managed between two testing and calibration tasks, cross-contamination may occur, affecting the accuracy of the calibration environment and even causing problems such as chemical residues, corrosion, or measurement deviations. Traditional operating methods usually rely on manual judgment to determine whether the liquid needs to be changed, which carries the risk of misoperation and is difficult to meet the requirements of high-reliability automated systems.

[0074] Therefore, in Figure 3 Based on this, please refer to Figure 4 The inspection and calibration method provided in this application embodiment also includes steps S10A to S10C.

[0075] S10A, the controller responds to the start inspection command and determines whether the liquid type required for this inspection and calibration task is consistent with the liquid type required for the previous inspection and calibration task; S10B, if inconsistent, prompt the user to replace the liquid and pause the inspection and calibration process until a confirmation signal that the liquid replacement has been completed is received. Then, in step S101, control the lifting device to move the multiple liquid level sensors it carries from the initial position to the liquid surface of the water storage and circulation device, and then descend to multiple preset depths in sequence to perform immersion sampling. S10C, if consistent, in step S101, the control lifting device moves the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage circulation device, and then descends to multiple preset depths in sequence to perform immersion sampling.

[0076] In this embodiment, when the controller receives the start inspection command, it first retrieves the liquid type information required for this inspection and calibration task and logically compares it with the liquid type used in the previous task. Optionally, the liquid type information is recorded as a key process parameter in the controller's storage unit, supporting cross-batch traceability and comparative analysis.

[0077] If the controller determines that the liquid type required for the current task is different from the previous one, it generates a prompt signal to notify the user that the liquid needs to be replaced. Optionally, the prompt signal can be delivered via audible and visual alarms, text messages pushed to the human-machine interface, or remote terminals to ensure that operators are promptly informed of the status change. Simultaneously, the controller will pause the entire inspection and calibration process, preventing the lifting device from performing any movement operations to avoid invalid or erroneous sampling operations in environments containing non-target liquids. Execution of subsequent steps will only resume after the user completes the liquid replacement operation and actively sends a confirmation signal to the controller. Optionally, the operator can trigger the generation and uploading of the confirmation signal by clicking the "Liquid Replacement Complete" button on the human-machine interface.

[0078] If the controller determines that the liquid type required for this task is the same as that of the previous task, it considers the calibration environment to meet the requirements and proceeds directly to the next stage without additional intervention. This involves controlling the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water circulation device, and then sequentially descending to multiple preset depths for immersion sampling. This approach adapts to the production needs of frequent liquid changes while avoiding unnecessary shutdowns for verification during continuous operation with the same liquid, thus improving overall operational efficiency.

[0079] It should be understood that after the inspection and calibration of the level sensor is completed, there may be residual liquid in the water circulation device that has been diverted to the second water tank due to level adjustment or liquid replacement. If this part of the liquid is not effectively recovered and collected after the operation, it will not only cause waste of resources, but may also affect the matching of the total amount of liquid required for the next calibration task. In some cases, the residual liquid may even lead to the growth of microorganisms or chemical deterioration, thereby affecting the purity and consistency of the subsequent calibration environment.

[0080] Therefore, please refer to again Figure 4 After step S103, the inspection and calibration method provided in this application embodiment further includes steps S106 to S107.

[0081] S106, After receiving the test results reported by each liquid level sensor, the controller sends a command to the pump control device to end the operation. S107 After receiving the end-of-operation command, the water pump control device starts the circulating water pump to send the liquid in the second water tank back to the first water tank through the circulating water circuit.

[0082] In this embodiment, after receiving the test results reported by all liquid level sensors, the controller determines that the test calibration task has been completed and sends a work stop command to the water pump control device. After receiving the work stop command, the water pump control device starts the circulating water pump. The circulating water pump starts running and drives the liquid accumulated in the second water tank to be transported back to the first water tank through the circulating water path, realizing the directional return and centralized storage of the liquid.

[0083] Optionally, after receiving the inspection results reported by all liquid level sensors, the controller can further summarize them into a quality inspection report. Based on the quality inspection report, the operator first sorts out the good products and the defective products, then sends the good products to the good product warehouse, and re-inspects the collected defective products. Those that pass the re-inspection are also sent to the good product warehouse, and those that still fail the re-inspection are scrapped.

[0084] Compared with the prior art, the embodiments of this application have the following beneficial effects: First, by constructing an inspection and calibration system consisting of a controller, a water storage and circulation device, a lifting device, and multiple liquid level sensors to be calibrated, batch automated inspection and calibration of liquid level sensors is achieved. Traditional calibration methods usually rely on manual operation, which can only process a single sensor at a time, resulting in low efficiency and susceptibility to human interference. In contrast, this application utilizes a lifting device to simultaneously carry multiple liquid level sensors and completes multi-point immersion sampling under the unified scheduling of the controller, thereby increasing the number of calibrations per unit time and effectively solving the problem of low operating efficiency in the prior art.

[0085] Secondly, the first water tank is equipped with an overflow port. When the internal liquid level exceeds the preset height, the excess liquid automatically flows into the second water tank, thereby maintaining the stability of the liquid level in the first water tank. This avoids measurement errors caused by liquid level fluctuations, improves the repeatability and data reliability of each sampling, and at the same time, after the task is completed, the liquid in the second water tank can be returned to the first water tank through the circulating water pump and circulating water circuit, forming a closed liquid management mechanism, which saves resources and facilitates subsequent continuous operation.

[0086] Third, the controller is responsible for the timing control and status management of the entire inspection and calibration process. From responding to the start inspection command and coordinating the spatial movement of the lifting device, to triggering the data acquisition of each sensor and receiving the reported inspection results, and then issuing the end operation command to start liquid recovery, all actions are automatically executed according to the preset logic without human intervention. This eliminates the uncertainty and deviation caused by non-standard operation and ensures the consistency and traceability of calibration accuracy.

[0087] Fourth, the controller compares the liquid type required for the current task with that required for the previous task to determine whether to prompt for a liquid change and pause the process. It will continue to execute subsequent steps only after receiving a confirmation signal from the user. This effectively prevents cross-contamination between different media, ensures that the calibration environment meets the actual application requirements, and enhances the system's adaptability and safety in scenarios with multiple varieties and changing operating conditions.

[0088] Fifth, after each liquid level sensor is calibrated, it can generate a personalized calibration model based on the relationship between the liquid level data collected at multiple preset depths and the corresponding preset depth range. This model is used to dynamically compensate for its own measurement values ​​after leaving the factory, thereby improving its long-term accuracy in actual use.

[0089] Finally, after receiving the test results reported by all liquid level sensors, the controller controls the lifting device to rise to a safe position and then return to the initial position, avoiding collisions or scratches of mechanical parts while they are still in the liquid state, thus improving the safety and lifespan of the equipment.

[0090] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A testing and calibration method, characterized in that, The system is used in an inspection and calibration system, which includes a controller, a water storage and circulation device, a lifting device, and multiple liquid level sensors to be calibrated. The controller is connected to the water storage and circulation device, the lifting device, and each of the liquid level sensors. The water storage and circulation device is used to provide a calibration environment with a constant liquid level; the lifting device is used to carry the multiple liquid level sensors to be calibrated. The inspection and calibration method includes: The controller responds to the start inspection command and controls the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then descends to multiple preset depths in sequence for immersion sampling. The controller triggers each liquid level sensor to collect corresponding liquid level data at each preset depth; Each liquid level sensor checks its own compliance based on the liquid level data it collects at each preset depth, obtains the check result, and reports it to the controller.

2. The testing and calibration method as described in claim 1, characterized in that, The testing and calibration method further includes: If the inspection result is qualified, each of the liquid level sensors generates a calibration model based on all the liquid level data and the plurality of preset depths. The calibration model is used to calibrate the measurement value of the liquid level sensor after it leaves the factory.

3. The testing and calibration method as described in claim 1, characterized in that, The testing and calibration method further includes: After receiving the inspection results reported by each of the liquid level sensors, the controller controls the lifting device to rise to a preset safe position and then return to the initial working position.

4. The testing and calibration method as described in claim 1, characterized in that, Each liquid level sensor checks its own compliance based on the liquid level data it collects at each preset depth, including the following steps: Sequentially determine whether the liquid level data collected at each preset depth is within the corresponding preset depth range; If any of the liquid level data exceeds the corresponding preset depth range, the liquid level sensor is deemed unqualified. If each of the liquid level data points is within the corresponding preset depth range, then the liquid level sensor is deemed qualified.

5. The testing and calibration method as described in claim 1, characterized in that, The testing and calibration method further includes: The controller responds to the start test command and determines whether the liquid type required for this test and calibration task is consistent with the liquid type required for the previous test and calibration task. If there is a discrepancy, the user is prompted to replace the liquid and the inspection and calibration process is paused until a confirmation signal indicating that the liquid replacement has been completed is received. Then, the step of controlling the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then descending to multiple preset depths in sequence for immersion sampling is executed. If they match, then the step of controlling the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then sequentially descending to multiple preset depths for immersion sampling is executed.

6. The testing and calibration method as described in claim 1, characterized in that, The water storage and circulation device includes a first water tank, a second water tank, a circulating water pump, a water pump control device, and a circulating water path. The water pump control device is connected to both the controller and the circulating water pump. The circulating water path is located between the first water tank and the second water tank, and the circulating water pump is connected to the circulating water path. The first water tank is provided with an overflow port. When the liquid level in the first water tank exceeds a preset height, excess liquid flows into the second water tank through the overflow port. The testing and calibration method further includes: After receiving the test results reported by each of the liquid level sensors, the controller sends a command to the water pump control device to end the operation. Upon receiving the end-of-operation command, the water pump control device activates the circulating water pump to return the liquid in the second water tank to the first water tank via the circulating water path.

7. An inspection and calibration system, characterized in that, The inspection and calibration system includes a controller, a water storage and circulation device, a lifting device, and multiple liquid level sensors to be calibrated. The controller is connected to the water storage and circulation device, the lifting device, and each of the liquid level sensors. The water storage and circulation device is used to provide a calibration environment with a constant liquid level; the lifting device is used to carry the multiple liquid level sensors to be calibrated. The controller is used to respond to the start inspection command, control the lifting device to move the multiple liquid level sensors it carries from the initial position to above the liquid surface of the water storage and circulation device, and then descend to multiple preset depths in sequence for immersion sampling; The controller is also configured to trigger each liquid level sensor to collect corresponding liquid level data at each preset depth; Each of the liquid level sensors is used to check whether it is qualified based on the liquid level data it collects at each preset depth, obtain the check result and report it to the controller.

8. The inspection and calibration system as described in claim 7, characterized in that, The water storage and circulation device includes a first water tank, a second water tank, a circulating water pump, a water pump control device, and a circulating water path. The water pump control device is connected to the controller and the circulating water pump. The circulating water path is located between the first water tank and the second water tank. The circulating water pump is connected to the circulating water path. The first water tank is equipped with an overflow port. When the liquid level in the first water tank exceeds a preset height, the excess liquid flows into the second water tank through the overflow port. The controller is also configured to send a termination command to the pump control device after receiving the test results reported by each of the liquid level sensors. The water pump control device is used to start the circulating water pump after receiving the end-of-operation instruction, so as to send the liquid in the second water tank back to the first water tank through the circulating water circuit.

9. The inspection and calibration system as described in claim 8, characterized in that, The water storage and circulation device also includes a movable base installed at the bottom of the first water tank; When the controller detects that the liquid type required for the current inspection and calibration task is inconsistent with the liquid type required for the previous inspection and calibration task, and prompts the user to change the liquid, the user replaces the first water tank entirely using the movable base.

10. The inspection and calibration system as described in claim 7, characterized in that, The lifting device includes a support frame, a suspended basket, and a lifting and rotating control mechanism, wherein the lifting and rotating control mechanism is connected to the controller. The bracket is vertically fixed, and the lifting and rotating control mechanism is slidably mounted on the bracket to drive the basket to lift vertically along the bracket and rotate around the vertical axis to a specified angle. The basket is fixed to the lower end of the lifting and rotating control mechanism and is used to simultaneously fix multiple liquid level sensors to be calibrated. The basket adopts a hollow structure to ensure that each liquid level sensor is in full contact with the liquid in the water storage and circulation device without affecting the stability of the liquid level.

Images