Device and method for detecting solid level in container

Abstract

The invention discloses a device and method for detecting the solid level in a container, and relates to the technical field of solid level detection. A device for detecting the solid level in a container comprises a rotating shaft which is located in an external container and used for being rubbed with materials to be detected in the external container during rotation so as to enable the torque of the rotating shaft to change; the output motor is used for providing power for the rotating shaft; two ends of the coupler are respectively connected with the rotating shaft and the output motor, and the output motor drives the rotating shaft to rotate through the coupler; the torque sensor is mounted on the rotating shaft and used for detecting the torque of the rotating shaft; the material level displayer is connected with the torque sensor and used for receiving the torque signals of the torque sensor and converting the torque signals into material level numerical values. The method solves the problems that the method cannot adapt to complex conditions during measurement, overcomes interference and is large in measurement result error.

Description

Technical Field

[0001] This invention relates to the field of solid level detection technology, and specifically to a device and method for detecting solid level inside a container. Background Technology

[0002] Level measurement involves measuring the height of material in a container. Materials are generally classified as liquids or solids. The level of a liquid is typically called the liquid level, while the level of a solid is often referred to as the material level. Currently, methods commonly used to measure the level of solid particles in a container can be divided into two categories:

[0003] The first type of method utilizes the change in solid particle level to cause a change in the capacitance or resistance of the detection element. The processor converts the change in capacitance or resistance into a corresponding electrical signal and transmits it to a secondary instrument to detect the material level. This type of detection structure is simple to implement, easy to install, low in cost, convenient to use, has no mechanical moving parts, and has a long service life. For example, the prior art CN105784062A discloses a method and device for detecting the material level in a material silo. This technology obtains the level value data by detecting the capacitance in the material silo. The prior art CN105371920A discloses a pneumatic level detection device. This technology uses the pressure deformation of a soft measuring sleeve under the pressure of the material to connect the static and moving contacts on the same plane of the conductive wire. When the corresponding contact switches close, and all the contact switches on all surfaces of the guide tube under this plane are closed, the corresponding precision resistors are short-circuited, finally reducing the resistance of the resistor network. The amount of this resistance reduction is proportional to the actual height of the material, thereby obtaining the level value.

[0004] The second type of method utilizes radiation, ultrasound, or electromagnetic waves actively emitted by the detection device. The level gauge itself receives and processes the reflected radiation, ultrasound, or electromagnetic waves to achieve material position detection. For example, the prior art CN112787075A discloses a high-frequency radar level gauge, which uses a high-frequency radar level gauge and a circular tubular extended antenna to emit electromagnetic waves to achieve material position detection.

[0005] The aforementioned technologies all involve measuring the level of solid particles inside containers. However, in actual working conditions, complex situations arise inside containers, such as dust interference and unclear level interfaces. Existing X-ray level gauges emit radiation that can cause contamination, while ultrasonic level gauges are only suitable for applications requiring high precision in measuring the interface. Capacitive (resistive) level gauges may have their measurement accuracy affected by material adhering to the container wall or irregular solid shapes. Furthermore, none of the aforementioned detection devices can perform intelligent corrections, resulting in significant measurement errors. Summary of the Invention

[0006] The technical problem to be solved by the present invention is that existing solid level detection devices in containers cannot adapt to complex situations, overcome interference, and have large measurement errors.

[0007] On the one hand, the purpose of this invention is to provide a device for detecting the level of solids in a container, which solves the problems of not being able to adapt to complex situations, overcome interference, and have large measurement errors.

[0008] On the other hand, the purpose of this invention is to provide a method for detecting the solid level inside a container, which is used in conjunction with a device for detecting the solid level inside a container to detect the solid level.

[0009] This invention is achieved through the following technical solution:

[0010] This invention provides a device for detecting the level of solids inside a container, comprising:

[0011] The rotating shaft, located inside the outer container, is used to rotate and rub against the material to be tested inside the outer container to change the torque of the rotating shaft.

[0012] Output motor, used to provide power to the rotating shaft;

[0013] The coupler is connected at both ends to the rotating shaft and the output motor, respectively, and the output motor drives the rotating shaft to rotate through the coupler.

[0014] A torque sensor, mounted on the shaft, is used to detect the torque of the shaft.

[0015] A level indicator, connected to a torque sensor, is used to display the level value.

[0016] As one possible design, the above-mentioned solid level detection device in the container also includes a speed reducer, the input shaft of which is connected to the output shaft of the output motor, and the output shaft of which is connected to a coupler to increase the output torque.

[0017] As one possible design, the above-mentioned solid level detection device in the container also includes a stirring blade, which is fixed on the rotating shaft to improve the accuracy and stability of the measurement and to smooth the interface of the material to be measured.

[0018] As one possible design, there are multiple agitator blades, which are fixedly distributed along the axis of rotation.

[0019] As one possible design, multiple stirring blades are evenly and symmetrically distributed on the rotating shaft.

[0020] As one possible design, the above-mentioned solid level detection device in the container also includes a processor, which is connected to a level display and a torque sensor respectively. The processor converts the torque signal to obtain torque numerical data and sends it to the level display, which then displays the data.

[0021] As one possible design, the above coupler is a magnetic coupler.

[0022] The present invention also provides a method for detecting the level of solids inside a container, comprising the following steps:

[0023] The torque sensor detects the shaft torque of the material to be tested when it is filled to different levels in the external container. The torque signal is converted into a digital torque signal and output to the level display for recording, thus obtaining the torque-level relationship.

[0024] Place the rotating shaft into an external container containing the material to be tested, start the output motor, and the output motor drives the rotating shaft to rotate through the coupler. The torque of the rotating shaft changes with the level of the material to be tested.

[0025] The torque sensor detects the shaft torque and converts it into a digital torque signal, which is then output to the level display.

[0026] The level indicator converts the torque signal into level data and displays it.

[0027] As one possible design, the above torque is calculated using the following formula:

[0028] T = K × ρ × N 3 ×(d / D) 2.5 ×D 5 ×n 0.6 ×η

[0029] T: Torque, Nm;

[0030] K: A constant related to the geometry of the stirrer;

[0031] ρ: Density of particulate matter, kg / m³ 3 ;

[0032] N: revolutions per minute, r / min;

[0033] d: diameter of the agitator blade, in meters;

[0034] D: Inner diameter of the container, in meters;

[0035] n: Number of agitator blades;

[0036] η: Efficiency of the agitator.

[0037] As one possible design, the above level is calculated using the following formula:

[0038] H = T / (ρ × V × g × η)

[0039] H: Level, m;

[0040] T: Torque, Nm;

[0041] ρ: Density of particulate matter, kg / m³ 3 ;

[0042] V: Volume of the material, m 3；

[0043] g: acceleration due to gravity, 9.81 m / s² 2 ;

[0044] η: Efficiency of the agitator.

[0045] This invention operates based on the following principle: When torque acts on a rotating shaft, the shaft undergoes torsional deformation. By placing a strain gauge (part of a torque sensor) on the rotating shaft, the output phase of the torque sensor can be measured, yielding the torque value. When the torque sensor is not under torque load, the strain gauge does not generate a signal, and the sensor output is zero voltage or close to zero voltage. Furthermore, the torque sensor boasts extremely high accuracy and stability, typically reaching 0.1% or higher, resulting in highly accurate torque measurements. By first measuring the torque at different known material levels, a torque-level relationship is obtained. During testing, after measuring the torque, the relationship is converted to obtain the solid material level information.

[0046] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0047] This invention involves placing the device in a container holding the material to be tested, activating an output motor, and driving a rotating shaft. As the solid level changes, the frictional force between the shaft and the solid changes, resulting in a change in the torque acting on the shaft. The actual torque is measured by a torque sensor, and the torque data is converted into level data by a level display, thus determining the actual material level. The entire operation is simple, and the torque test is unaffected by dust inside the container, unclear level interfaces, or irregular solid shapes, making it suitable for various complex situations and enabling accurate detection of solid levels. Attached Figure Description

[0048] To more clearly illustrate the technical solutions of the exemplary embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of the present invention and should not be considered as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort. In the drawings:

[0049] Figure 1 This is one of the structural schematic diagrams of a device for detecting the level of solid matter inside a container according to the present invention;

[0050] Figure 2 This is a second schematic diagram of the structure of a device for detecting the level of solid matter inside a container according to the present invention;

[0051] Figure 3 This is a circuit block diagram of a device for detecting the level of solid matter inside a container according to the present invention.

[0052] The attached diagram shows the markings and corresponding component names:

[0053] 1-Shaft; 2-Output motor; 3-Coupler; 4-Torque sensor; 5-Level indicator; 6-Reducer; 7-Agitator blade; 8-Processor; 9-External container. Detailed Implementation

[0054] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of the present invention are only used to explain the present invention and are not intended to limit the present invention.

[0055] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0056] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0057] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. 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. Therefore, they should not be construed as limitations on this invention.

[0058] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0059] Existing devices for detecting solid levels have problems such as being unable to adapt to complex situations, overcome interference, and produce large measurement errors.

[0060] In a first aspect, the present invention provides a device for detecting the level of solid matter inside a container, referring to... Figure 1-2 This detection device can obtain solid level data inside the container by detecting changes in the torque of the rotating shaft 1. The device includes a rotating shaft 1, an output motor 2, a coupler 3, a torque sensor 4, and a level display 5. The rotating shaft 1 is located inside the outer container 9, preferably at the center of the outer container 9. When the rotating shaft is driven to rotate by the output motor 2, the rotation of the rotating shaft 1 generates relative motion with the material to be measured inside the outer container 9, resulting in friction between the rotating shaft 1 and the material. When the material level changes, the friction between the rotating shaft 1 and the material changes, thus changing the torque on the rotating shaft 1. The output motor 2 is connected to the rotating shaft 1 through the coupler 3, providing rotational power to the rotating shaft 1. It can be a servo motor, a stepper motor, or other motor capable of driving the rotating shaft 1. The two ends of the coupler 3 are connected to the rotating shaft 1 and the output motor 2 respectively, transmitting the rotational force generated by the output motor 2 to the rotating shaft 1 and protecting the output motor 2. The coupler can be a mechanical coupler. A hydraulic or magnetic coupler is used; the torque sensor 4 is installed on the upper end of the rotating shaft 1. When the rotating shaft 1 rotates, the friction force on the rotating shaft 1 changes due to the change in the material level, and thus the torque on the rotating shaft 1 also changes. When the torque acts on the rotating shaft 1, the rotating shaft 1 will undergo torsional deformation. The strain gauge of the torque sensor 4 is placed on the rotating shaft 1, which can measure the output phase of the torque sensor 4 to obtain the torque value. When the torque sensor 4 is not under torque load, the strain gauge will not generate a signal, and the sensor output is zero voltage or close to zero voltage. The torque sensor 4 has very high accuracy and stability, usually reaching 0.1% or higher, and has the characteristics of fast response, high accuracy, and stable signal. The level display 5 is electrically connected to the torque sensor 4 to display the level value.

[0061] In this embodiment, during use, the rotating shaft 1 is placed at the center of the outer container 9 and inserted into the material to be measured. Driven by the output motor 2, the rotating shaft 1 rotates. At this time, the torque sensor 4 can measure the torque data and transmit the torque data to the level display 5, which then displays the level value.

[0062] In some embodiments of the present invention, reference is made to... Figure 1-2 The above-mentioned solid level detection device in the container also includes a reducer 6. The input shaft of the reducer 6 is connected to the output shaft of the output motor 2, and the output shaft of the reducer 6 is connected to the coupler 3. The reducer 6 can reduce the input speed and increase the output torque.

[0063] In some embodiments of the present invention, reference is made to... Figure 1-2 The aforementioned device for detecting the solid level within the container also includes a stirring blade 7. Since the surface of the material is not necessarily flat, existing technologies such as X-ray, ultrasonic, or electromagnetic wave detection are prone to inaccurate data. This invention addresses this by providing a stirring blade 7 on the side of the rotating shaft 1, with the plane of the stirring blade 7 parallel to the axial direction of the rotating shaft 1. This allows the stirring blade 7 to rotate along with the rotating shaft 1, smoothing the surface of the material and thus accurately measuring the actual level data. This ensures accurate and stable torque measurement. Preferably, when there is only one stirring blade 7, it is fixed to the bottom of the rotating shaft 1. Preferably, the connection between the stirring blade 7 and the rotating shaft 1 is a fixed connection, which can be welding, snap-fitting, or other connection methods.

[0064] In some embodiments of the present invention, reference is made to... Figure 1 The aforementioned stirring blades 7 are multiple, and the multiple stirring blades 7 are dispersed and fixed along the axial direction of the rotating shaft 1. This arrangement can improve the smoothing speed. Preferably, the multiple stirring blades 7 are not evenly distributed on the rotating shaft 1.

[0065] In some embodiments of the present invention, reference is made to... Figure 2 The aforementioned multiple stirring blades 7 are evenly and symmetrically distributed on the rotating shaft 1.

[0066] In some embodiments of the present invention, reference is made to... Figure 3 The solid level detection device in the container also includes a processor 8, which is connected to the level display 5 and the torque sensor 4. The processor 8 can be a computer or a PLD programmable logic device. The processor 8 converts the torque signal to obtain torque numerical data and sends the torque signal to the level display 5 for display.

[0067] In some embodiments of the present invention, reference is made to... Figure 1-2The aforementioned coupler 3 is a magnetic coupler. Since material testing inevitably generates dust, which can interfere with data detection, the magnetic coupler utilizes a magnetic field to transmit power, driving a rotating shaft inside the container, thus achieving torque transmission from the motor to the shaft. There is no mechanical connection between the motor and the shaft, easily solving the container's sealing problem. There is no friction between the seals, eliminating dust interference and frictional power consumption—factors affecting torque transmission and detection—ensuring accurate test results. The magnetic coupler is low-cost and low-maintenance; it offers high process control accuracy (up to 0.1%); energy savings of 25%-66%; simple structure, small size, easy installation, adaptability to various harsh environments, and produces no electromagnetic harmonics or pollution. In practical use, the copper rotor at the output motor 2 is the driving wheel, and the permanent magnet rotor at the shaft is the driven wheel. When the copper rotor driven by the output motor 2 rotates, its magnetic field also rotates, generating eddy currents in the permanent magnet rotor, causing it to drive the shaft to rotate. Magnetic couplers improve upon the shortcomings of current solid level detection methods and ensure the accuracy, stability, and economy of the detection device.

[0068] Preferably, the torque sensor 4 is a sensor based on strain gauge, electronic measurement technology, and signal processing technology used to measure torsional torque. The torque sensor 4 can accurately measure static and dynamic torque, torsion angle, and their rate of change within a linear range, and convert them into a standard electrical signal output. Its output signal range is preferably ±5V or +10V, and it can also output a digital signal.

[0069] When using this invention, the signal line output must not be short-circuited to ground or power supply. The output current of the instrument signal line should not exceed 10mA, and the shielding layer of the shielded cable must be connected to the common terminal (power ground) of the +15V power supply. This can eliminate external interference and improve the accuracy of the measured values.

[0070] Secondly, the present invention also provides a method for detecting the level of solid matter inside a container, comprising the following steps:

[0071] The torque sensor 4 detects the shaft torque of the material to be tested when it is filled to different levels in the external container 9. The torque signal is converted into a digital torque signal and output to the level display 5 for recording, thus obtaining the torque-level relationship.

[0072] Place the rotating shaft 1 into the external container 9 containing the material to be tested, start the output motor 2, and the output motor 2 drives the rotating shaft 1 to rotate through the coupler 3. The torque of the rotating shaft 1 changes with the level of the material to be tested.

[0073] Torque sensor 4 detects the torque of shaft 1 and converts it into a digital signal of torque, which is then output to processor 8 for data processing and transmission to level display 5.

[0074] The level display 5 displays level data based on the torque-level relationship and the torque digital signal.

[0075] In some embodiments of the present invention, the torque is calculated using the following formula:

[0076] T = K × ρ × N 3 ×(d / D) 2.5 ×D 5 ×n 0.6 ×η

[0077] T: Torque, Nm;

[0078] K: A constant related to the geometry of the stirrer;

[0079] ρ: Density of particulate matter, kg / m³ 3 ;

[0080] N: revolutions per minute, r / min;

[0081] d: diameter of the agitator blade, in meters;

[0082] D: Inner diameter of the container, in meters;

[0083] n: Number of agitator blades;

[0084] η: Efficiency of the agitator.

[0085] Preferably, the K value is between 2.2 and 2.5.

[0086] In some embodiments of the present invention, the level is calculated using the following formula:

[0087] H = T / (ρ × V × g × η)

[0088] H: Level, m;

[0089] T: Torque, Nm;

[0090] ρ: Density of particulate matter, kg / m³ 3 ;

[0091] V: Volume of the material, m 3；

[0092] g: acceleration due to gravity, 9.81 m / s² 2 ;

[0093] η: Efficiency of the agitator.

[0094] Preferably, the above η is 0.7-0.9, and more preferably 0.8.

[0095] This invention differs from traditional capacitive, resistive, acoustic, and ray-based level measurement methods. Instead, it detects the level by measuring the torque of the rotating shaft, which is simple to operate, reduces energy consumption, and effectively improves the accuracy of level detection.

[0096] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. 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 device for detecting the level of solid matter inside a container, characterized in that, include The rotating shaft, located inside the outer container, is used to rotate and rub against the material to be tested inside the outer container to change the torque of the rotating shaft. An output motor is provided to power the rotating shaft; A coupler is connected at both ends to the rotating shaft and the output motor, respectively, and the output motor drives the rotating shaft to rotate through the coupler; A torque sensor, mounted on the rotating shaft, is used to detect the torque of the rotating shaft; A level display, connected to the torque sensor, is used to display the level value.

2. The device for detecting the solid level inside a container according to claim 1, characterized in that, It also includes a speed reducer, the input shaft of which is connected to the output shaft of the output motor, and the output shaft of which is connected to a coupler to improve the output torque.

3. The device for detecting the solid level inside a container according to claim 1, characterized in that, It also includes stirring blades, which are fixed on the rotating shaft to improve measurement accuracy and stability and to smooth the interface of the material to be tested.

4. The device for detecting the solid level inside a container according to claim 3, characterized in that, The number of stirring blades is multiple, and the multiple stirring blades are dispersed and fixed along the axis of the rotating shaft.

5. The device for detecting the solid level inside a container according to claim 4, characterized in that, Multiple stirring blades are evenly and symmetrically distributed on the rotating shaft.

6. The device for detecting the solid level inside a container according to claim 1, characterized in that, It also includes a processor, which is connected to a level display and a torque sensor respectively. The processor converts the torque signal to obtain torque numerical data and sends it to the level display for display.

7. The device for detecting the solid level inside a container according to claim 1, characterized in that, The coupler is a magnetic coupler.

8. A method for detecting the solid level inside a container, characterized in that, A device for detecting the solid level inside a container as described in any one of claims 1 to 7, comprising the following steps: The torque sensor detects the shaft torque of the material to be tested when it is filled to different levels in the external container. The torque signal is converted into a digital torque signal and output to the level display for recording, thus obtaining the torque-level relationship. Place the rotating shaft into an external container containing the material to be tested, start the output motor, and the output motor drives the rotating shaft to rotate through the coupler. The torque of the rotating shaft changes with the level of the material to be tested. The torque sensor detects the shaft torque and converts it into a digital torque signal, which is then output to the level display. The level indicator converts the torque signal into level data and displays it.

9. The method for detecting the solid level inside a container according to claim 8, characterized in that, The torque is calculated using the following formula: T=K×ρ×N 3 ×(d / D) 2.5 ×D 5 ×n 0.6 ×η T: Torque, Nm; K: A constant related to the geometry of the stirrer; ρ: Density of particulate matter, kg / m³ 3 ; N: revolutions per minute, r / min; d: diameter of the agitator blade, in meters; D: Inner diameter of the container, in meters; n: Number of agitator blades; η: Efficiency of the agitator.

10. The method for detecting the solid level inside a container according to claim 9, characterized in that, The level is calculated using the following formula: H = T / (ρ × V × g × η) H: Level, m; T: Torque, Nm; ρ: Density of particulate matter, kg / m³ 3 ; V: Volume of the material, m 3； g: acceleration due to gravity, 9.81 m / s² 2 ; η: Efficiency of the agitator.

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