Oil dripping speed monitoring device and automatic monitoring method in high-temperature vacuum environment

Abstract

The invention discloses an oil dripping speed monitoring device in a high-temperature vacuum environment and an automatic monitoring method. The device comprises a vacuum chamber, a heating rod, an optical fiber sensing system comprising a vacuum-atmosphere isolation structure, a photoelectric conversion unit, a counting unit and a data processing system. The vacuum chamber and the heating rod provide a high-temperature vacuum environment, optical signals of oil drops in the high-temperature vacuum chamber are collected through the optical fiber sensing system, the vacuum-atmosphere isolation structure seals the vacuum side and the atmosphere side and transmits the optical signals, the optical signals are converted into electric signals, and then data collection and data processing are conducted. And a special database for the oil dripping speed monitoring process is established. The problems that in an existing testing method, the oil dripping speed cannot be automatically monitored in an omnibearing mode, the testing process is still completely guaranteed by personnel, the manual testing efficiency is low, and the whole process is not controlled are solved. The automation level, the detection efficiency, the accuracy and the backtracking efficiency are greatly improved, and the oil filling quality and the consistency of the instrument are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of instrument oil-filled vacuum testing technology, and in particular to an oil dripping rate monitoring device and automatic monitoring method under high temperature vacuum conditions. Background Technology

[0002] Liquid flotation technology is one of the key technologies of instruments. If there are air bubbles in the instrument during the oil filling process, the movement of the air bubbles will generate interference torque, affecting the accuracy of the instrument. At present, the fluctuation of the dripping time during the oil filling process of the instrument is large. If the dripping is too fast, air bubbles may be introduced, which will have a certain impact on the accuracy of the instrument. Therefore, it is necessary to control the consistency of the dripping speed.

[0003] Existing testing methods cannot automatically monitor the dripping speed in all aspects, and the testing process still relies entirely on human intervention. This results in low efficiency and uncontrollable processes, posing certain risks. Summary of the Invention

[0004] The technical problem solved by this invention is to overcome the shortcomings of the prior art and provide a dripping rate monitoring device and automatic monitoring method under high temperature vacuum environment. This device enables real-time monitoring of dripping rate, automatic statistics of dripping volume, intelligent early warning of dripping rate, and judgment and adjustment of dripping valve status under high temperature vacuum environment. It improves the level of automation, detection efficiency, accuracy and backtracking efficiency, realizes the full electronicization of dripping rate process information, and improves the quality and consistency of instrument filling.

[0005] The technical solution of the present invention is: a dripping rate monitoring device under high temperature vacuum environment, comprising: a vacuum chamber, a heating rod, an optical fiber sensing system, a photoelectric conversion unit, a counting unit, and a data processing system; The vacuum chamber is used to provide a vacuum environment for the oil dripping circuit; the heating rod is mounted on the chassis in the vacuum chamber and is used to control the temperature of the oil dripping circuit through thermal radiation. The fiber optic sensing system is installed in the area below the oil cup funnel in the vacuum chamber to provide a light source and collect the light signal of the oil droplets; The photoelectric conversion unit is connected to the fiber optic sensing system and is used to convert the collected optical signals into electrical signals; The counting unit is connected to the photoelectric conversion unit and is used to count oil droplets based on electrical signals; The data processing system is connected to the counting unit and is used to process the collected data, automatically monitor the dripping speed, and automatically calculate the real-time speed of each drop, the distribution of the dripping speed, the average dripping amount per unit time, automatically generate a dripping speed monitoring curve, and evaluate the oil filling stability.

[0006] Furthermore, the vacuum chamber is composed of a glass bell jar and a base, and the bottom surface of the glass bell jar and the base are sealed with a fluororubber sealing ring.

[0007] Furthermore, the optical fiber sensing system includes a vacuum-side optical fiber and an atmospheric-side optical fiber, with a vacuum-atmosphere isolation structure between them to seal the vacuum side and the atmospheric side, thereby achieving efficient transmission and coupling of optical signals.

[0008] Furthermore, the light source in the fiber optic sensing system is a red 4-element LED with a wavelength of 660nm, and the detection method is transmission-type.

[0009] Furthermore, the counting unit and the photoelectric conversion unit are connected via RS485 and communicate using the MODBUS communication protocol, with a 24V power supply output.

[0010] Furthermore, the heating rod consists of four armored heating rods evenly distributed on the chassis.

[0011] Furthermore, the data processing system is also used to establish a database for monitoring the oil dripping speed based on the collected data, so as to realize fully automated monitoring and traceability query of the oil dripping process.

[0012] This invention also relates to an automatic monitoring method for oil dripping rate under high temperature vacuum conditions, comprising the following steps: Step 1: Construct the oil dripping rate monitoring device under high temperature vacuum environment as described in claim 1; Step 2: Place the instrument to be filled with oil in the vacuum chamber and load it to the predetermined vacuum level; turn on the heating rod to control the temperature of the vacuum chamber at the set value; Step 3: Set the solenoid valve parameters according to the oil filling requirements to control the dripping speed and dripping volume; Step 4: The fiber optic sensing system captures the light signals generated by the falling oil droplets in real time. Each droplet triggers a light signal pulse as it passes through the monitoring area. The light signal is transmitted to the photoelectric conversion unit and converted into an electrical signal. At the same time, the counting unit records the number of oil droplets and the time. Step 5: The data processing system automatically saves and processes oil droplet data in real time, including the real-time velocity of each oil droplet, the distribution of oil droplet velocity, and the average amount of oil dropped per unit time. Step 6: Issue an out-of-tolerance warning based on the oil droplet dripping rate; the out-of-tolerance warning method is as follows: determine whether the dripping rate is within the preset range; if yes, proceed to step 7; if no, automatically alarm and adjust the solenoid valve parameters, then proceed to step 4. Step 7: The real-time speed of each drop of oil, the distribution of the oil dripping speed, and the average amount of oil dripping per unit time are automatically calculated and automatically generated into an oil dripping speed monitoring curve in the format of dripping speed type-oil filling equipment-temperature-vacuum degree-instrument type-instrument number-process-inspection personnel-inspection time, which is used to evaluate the oil filling stability. Step 8: Create a database for monitoring the oil dripping rate.

[0013] Furthermore, in step 5, The formula for calculating the real-time velocity of each drop of oil is: V n =(T n -T n-1 ) / 1, where, V n Let T be the velocity of the nth drop of oil. n Let T be the time of the nth drop of oil. n-1 The time for the (n-1)th drop of oil.

[0014] The distribution of oil dripping velocity is determined by counting the number of oil droplets within a fixed time interval, calculated using the formula: V i =N i / ΔT, where, V i N represents the average drip rate during the i-th time interval. i This represents the number of oil droplets within a time interval ΔT, where ΔT represents a fixed time interval. The fixed time intervals are set according to requirements, and the time intervals increase sequentially in an arithmetic sequence, starting from 0.5 hours with a tolerance of 0.5 hours, and increasing to 12 hours. Formula for calculating the average oil dripping amount per unit time: V avg =N total / T total , where V avg N represents the average amount of oil dripped per unit time. total T represents the total number of oil droplets. total This indicates the total time of the oil droplets.

[0015] Furthermore, in step 8, the oil dripping rate monitoring process database includes: a dripping rate information database, an oil filling equipment information database, an instrument information database, a process parameter database, a personnel information database, and a detection process record database, which respectively store dripping rate related information, oil filling equipment related information, instrument related information, instrument process parameters, personnel configuration information, and detection process data records.

[0016] The advantages of this invention compared to the prior art are: (1) The present invention adopts an integrated vacuum chamber, heating rod, fiber optic sensing system, photoelectric conversion unit, counting unit and data processing system to realize real-time monitoring of oil dripping speed, automatic oil dripping volume statistics, intelligent early warning of dripping speed, and judgment and adjustment of oil dripping valve status under high temperature vacuum environment, which significantly improves the level of automation, monitoring efficiency and accuracy.

[0017] (2) The comprehensive recording technology of drip rate monitoring process information of the present invention greatly improves the comprehensiveness, accuracy and efficiency of data recording. The present invention collects drip rate information in real time, saves the monitoring process data and monitoring curves throughout the process, and saves them to a dedicated database. It automatically calculates the real-time speed of each drop of oil, the distribution of drip rate, the average amount of oil dripped per unit time, and automatically generates the drip rate monitoring curve, realizing the comprehensive electronicization of drip rate process information.

[0018] (3) This invention greatly improves data backtracking efficiency and product production efficiency. The establishment of the drip rate-specific database enables comprehensive recording and traceability of various information in the production process, providing strong support for the optimization of oil filling process parameters. At the same time, it helps management to make scientific and reasonable production plans and other decisions, thereby improving production efficiency.

[0019] (4) This invention improves the quality and consistency of instrument filling. By monitoring and adjusting the dripping speed in real time, this invention can effectively avoid filling quality problems caused by dripping too fast or too slow, such as the introduction of air bubbles and uneven dripping, thereby ensuring the dense filling of the instrument cavity with fluorinated oil and improving the quality and consistency of instrument filling. Attached Figure Description

[0020] Figure 1 This is a schematic cross-sectional view of the oil dripping rate monitoring device of the present invention; Figure 2 This is a schematic diagram of the structure of the vacuum chamber of the present invention; Figure 3 This is a schematic diagram of the oil dripping speed monitoring device of the present invention; Figure 4 This is a flowchart of the automatic oil dripping speed monitoring method of the present invention. Detailed Implementation

[0021] To better understand the technical solution of the present invention, the specific embodiments of the present invention are described below.

[0022] In a first aspect, embodiments of the present invention provide an oil dripping rate monitoring device under high temperature vacuum environment, including a vacuum chamber 1, an optical fiber sensing system 2, a photoelectric conversion unit 3, a counting unit 4, a data processing system 5, and a heating rod 6.

[0023] Reference Figure 1 As shown, vacuum chamber 1 is used to provide a vacuum environment for the oil dripping circuit. The vacuum environment provided by vacuum chamber 1 for the instrument in the oil-filled state is ≤3×10⁻⁶. -5 Pa; The heating rods 6 are uniformly distributed on the chassis 12 in the vacuum chamber 1 using armored design. Four heating rods 6 are used to control the temperature of the oil dripping circuit through thermal radiation. The total power of the four heating rods 6 can reach 2KW, and the temperature field is uniformly distributed in the range of 20℃ to 100℃.

[0024] Reference Figure 1 and Figure 3 As shown, the fiber optic sensing system 2 is installed in the area below the oil cup funnel in the vacuum chamber 1 to collect the optical signal of the oil droplets. The fiber optic sensing system 2 includes a vacuum-side fiber 21 and an atmospheric-side fiber 22, with a vacuum-atmosphere isolation structure 23 between them to seal the vacuum side and the atmospheric side and achieve efficient transmission and coupling of the optical signal, ensuring the stability and reliability of the optical signal in a vacuum environment. The light source of the fiber optic sensing system 2 is a red 4-element LED with a wavelength of 660nm on the emitting side. The detection method is transmission-type, with a fastest response time of 23μs. The vacuum-side heat resistance temperature is 350℃, and the atmospheric-side heat resistance temperature is 70℃.

[0025] Reference Figure 2 As shown, the vacuum chamber 1 consists of a glass bell jar 11 and a base 12. The bottom surface of the glass bell jar 11 and the base 12 are sealed with a fluororubber sealing ring, and an external reflective screen is added.

[0026] Reference Figure 3 As shown, the photoelectric conversion unit 3 is connected to the fiber optic sensing system 2 via Ethernet and is used to convert optical signals into electrical signals.

[0027] Reference Figure 3 As shown, the counting unit 4 and the photoelectric conversion unit 3 are connected via RS485 and communicate using the MODBUS communication protocol. The unit is powered by 24V and has an accuracy of ±1 pulse. It is used to count oil droplets.

[0028] Reference Figure 3 As shown, the data processing system 5 is connected to the counting unit 4 and is used to process the collected data, automatically monitor the dripping rate in real time, and automatically calculate the real-time rate of each drop, the distribution of the dripping rate, and the average dripping amount per unit time. It also automatically generates a dripping rate monitoring curve to evaluate the oil filling stability. Simultaneously, a dedicated database for the dripping rate monitoring process is established to achieve fully automated monitoring and efficient traceability of the dripping process.

[0029] This invention provides an automatic monitoring method for oil dripping rate under high-temperature vacuum conditions, referring to... Figure 4 As shown, this method includes the following: I. A dripping rate monitoring device for high-temperature vacuum environment was constructed. The system integrates a vacuum chamber 1, a heating rod 6, an optical fiber sensing system 2, a photoelectric conversion unit 3, a counting unit 4, and a data processing system 5.

[0030] II. Personnel Identification Methods: Before using the system, testing personnel must undergo a personnel identification process. This process integrates three identification methods: facial recognition, fingerprint recognition, and username and password input. All identification data is entered into a dedicated database for unified management, storage, and comparison. The personnel identification process is a critical security verification step before the testing system is operated, aiming to ensure that only authorized personnel can perform subsequent testing operations, thereby improving process controllability and data security.

[0031] 3. Place the instrument to be filled with oil in the vacuum chamber 1, start the vacuum system to reach the predetermined vacuum level; start the heating system to control the temperature of the vacuum chamber 1 at the set value.

[0032] 4. Set the solenoid valve parameters. Set the solenoid valve switching parameters according to the oil filling requirements to control the oil dripping speed and dripping volume.

[0033] 5. Automatic real-time acquisition of oil droplet signals throughout the process: During the oil filling and dripping process of the instrument, the fiber optic sensing system 2 captures the light signals generated by the falling oil droplets in real time. Each drop of oil triggers a light signal pulse when it passes through the monitoring area. The light signal is transmitted to the photoelectric conversion unit 3 and converted into an electrical signal. At the same time, the counting unit 4 records the number and time of the oil droplets, ensuring that the oil dripping process is monitored throughout.

[0034] VI. The entire process automatically saves oil droplet data in real time, and saves the data in Excel format, naming the data in the format of instrument type-instrument number-production date-process-inspection personnel-inspection time.

[0035] VII. The entire process involves automatic real-time data processing. The formula for calculating the real-time velocity of each drop of oil is: V n =(T n -T n-1 ) / 1, where, V n T is the velocity of the nth drop of oil (unit: seconds / drop). n T is the time (in seconds) for the nth drop of oil. n-1 The time (in seconds) for the (n-1)th drop is used to monitor fluctuations in the dripping rate in real time and ensure the stability of the dripping process.

[0036] The distribution of oil dripping rate is determined by counting the number of oil droplets within a fixed time interval (e.g., 0.5 hours, 1 hour, 1.5 hours...12 hours), calculated using the formula: V i =N i / ΔT, where, V i N represents the average drip rate (in drops per hour) during the i-th time interval. iThis formula represents the number of oil droplets (in drops) within a time interval ΔT, where ΔT represents a fixed time interval (in hours). It is used to evaluate the distribution of droplet rate changes over time. The fixed time intervals can be set according to requirements, and they increase sequentially in an arithmetic progression, starting from 0.5 hours with a common difference of 0.5 hours, increasing to 12 hours. The time intervals are 0.5 hours, 1 hour, 1.5 hours…12 hours.

[0037] Formula for calculating the average oil dripping amount per unit time: V avg =N total / T total , where V avg N represents the average amount of oil dripping per unit time (unit: drops / hour). total T represents the total number of oil droplets (unit: droplets). total This represents the total time of the oil droplet (in hours). This formula is used to evaluate the overall efficiency of the oil droplet.

[0038] 8. Fully automatic real-time detection and display of drip rate and over-tolerance warning. The over-tolerance warning method is to determine whether the drip rate is within the preset range. If it is, proceed to step 9; if not, automatically alarm and adjust the solenoid valve parameters, proceed to step 5, realize multi-level adjustment of oil drip rate, and ensure the stability and consistency of oil drip rate.

[0039] 9. Establish a dedicated database for monitoring the oil dripping rate, including: a dripping rate information database, an oil filling equipment information database, an instrument information database, a process parameter database, a personnel information database, and a testing process record database, which respectively store information related to dripping rate, oil filling equipment, instruments, instrument process parameters, personnel configuration information, and testing process data records.

[0040] The drip rate database provides multi-dimensional data integration and storage, data classification, statistics and visualization, anomaly warning and intelligent linkage, data security and access control. It supports multi-dimensional retrieval of historical data and can trace the drip rate changes, parameter adjustment records and qualification results of a single instrument throughout the entire oil filling process, realizing fully automated monitoring of the dripping process.

[0041] It is understood that this invention has been described through embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this invention. Furthermore, under the teachings of this invention, these features and embodiments can be modified to adapt to specific circumstances without departing from the spirit and scope of this invention. Therefore, this invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are protected by this invention.

[0042] The contents not described in detail in this specification are common knowledge to those skilled in the art.

Claims

1. A device for monitoring the rate of oil dripping under high temperature vacuum conditions, characterized in that, include: Vacuum chamber (1), heating rod (6), fiber optic sensing system (2), photoelectric conversion unit (3), counting unit (4), data processing system (5); The vacuum chamber (1) is used to provide a vacuum environment for the dripping circuit; the heating rod (6) is installed on the chassis (12) in the vacuum chamber (1) and is used to control the temperature of the dripping circuit by thermal radiation. The fiber optic sensing system (2) is installed in the area below the oil cup funnel in the vacuum chamber (1) to provide a light source and collect the light signal of the oil droplets; The photoelectric conversion unit (3) is connected to the optical fiber sensing system (2) and is used to convert the collected optical signal into an electrical signal. The counting unit (4) is connected to the photoelectric conversion unit (3) and is used to count oil droplets according to the electrical signal; The data processing system (5) is connected to the counting unit (4) to process the collected data, automatically monitor the dripping speed, and automatically calculate the real-time speed of each drop, the distribution of the dripping speed, the average dripping amount per unit time, automatically generate the dripping speed monitoring curve, and evaluate the oil filling stability.

2. The oil dripping rate monitoring device under high temperature vacuum environment according to claim 1, characterized in that: The vacuum chamber (1) is composed of a glass bell jar (11) and a base (12), and the bottom surface of the glass bell jar (11) and the base (12) are sealed with a fluororubber sealing ring.

3. The oil dripping rate monitoring device under high temperature vacuum environment according to claim 1, characterized in that: The fiber optic sensing system (2) includes a vacuum-side fiber optic cable (21) and an atmospheric-side fiber optic cable (22), with a vacuum-atmosphere isolation structure (23) between them to seal the vacuum side and the atmospheric side, thereby achieving efficient transmission and coupling of optical signals.

4. The oil dripping rate monitoring device under high temperature vacuum environment according to claim 1, characterized in that: The light source in the fiber optic sensing system (2) is a red 4-element LED with a wavelength of 660nm, and the detection method is transmission.

5. The oil dripping rate monitoring device under high temperature vacuum environment according to claim 1, characterized in that: The counting unit (4) is connected to the photoelectric conversion unit (3) via RS485 and communicates using the MODBUS communication protocol, with a 24V power supply output.

6. The oil dripping rate monitoring device under high temperature vacuum environment according to claim 1, characterized in that: The heating rod (6) consists of four armored heating rods evenly distributed on the chassis (12).

7. The oil dripping rate monitoring device under high temperature vacuum environment according to claim 1, characterized in that: The data processing system (5) is also used to establish a dripping speed monitoring process database based on the collected data, so as to realize fully automated monitoring and traceability query of the dripping process.

8. A method for automatically monitoring the oil dripping rate under high temperature vacuum conditions, characterized in that: Includes the following steps: Step 1: Construct the oil dripping rate monitoring device under high temperature vacuum environment as described in claim 1; Step 2: Place the instrument to be filled with oil in the vacuum chamber (1) and load it to the predetermined vacuum level; start the heating rod (6) to control the temperature of the vacuum chamber (1) at the set value; Step 3: Set the solenoid valve parameters according to the oil filling requirements to control the dripping speed and dripping volume; Step 4: The fiber optic sensing system (2) captures the light signal generated by the falling oil droplets in real time. Each droplet triggers a light signal pulse when it passes through the monitoring area. The light signal is transmitted to the photoelectric conversion unit (3) and converted into an electrical signal. At the same time, the counting unit (4) records the number of oil droplets and the time. Step 5: The data processing system (5) automatically saves and processes oil droplet data in real time, including the real-time velocity of each oil droplet, the distribution of oil droplet velocity, and the average amount of oil droplet per unit time. Step 6: Issue an out-of-tolerance warning based on the oil droplet dripping rate; the out-of-tolerance warning method is as follows: determine whether the dripping rate is within the preset range; if yes, proceed to step 7; if no, automatically alarm and adjust the solenoid valve parameters, then proceed to step 4. Step 7: The real-time speed of each drop of oil, the distribution of the oil dripping speed, and the average amount of oil dripping per unit time are automatically calculated and automatically generated into an oil dripping speed monitoring curve in the format of dripping speed type-oil filling equipment-temperature-vacuum degree-instrument type-instrument number-process-inspection personnel-inspection time, which is used to evaluate the oil filling stability. Step 8: Create a database for monitoring the oil dripping rate.

9. The automatic monitoring method for oil dripping rate under high temperature vacuum environment according to claim 8, characterized in that: In step 5, The formula for calculating the real-time velocity of each drop of oil is: V n =(T n -T n-1 ) / 1, where, V n Let T be the velocity of the nth drop of oil. n Let T be the time of the nth drop of oil. n-1 The time for the (n-1)th drop of oil. The distribution of oil dripping velocity is determined by counting the number of oil droplets within a fixed time interval, calculated using the formula: V i =N i / ΔT, where, V i N represents the average drip rate during the i-th time interval. i This represents the number of oil droplets within a time interval ΔT, where ΔT represents a fixed time interval. The fixed time intervals are set according to requirements, and the time intervals increase sequentially in an arithmetic sequence, starting from 0.5 hours with a tolerance of 0.5 hours, and increasing to 12 hours. Formula for calculating the average oil dripping amount per unit time: V avg =N total / T total , where V avg N represents the average amount of oil dripped per unit time. total T represents the total number of oil droplets. total This indicates the total time of the oil droplets.

10. The method for automatically monitoring the oil dripping rate under high temperature vacuum environment according to claim 8, characterized in that: In step 8, the oil dripping rate monitoring process database includes: a dripping rate information database, an oil filling equipment information database, an instrument information database, a process parameter database, a personnel information database, and a detection process record database, which respectively store dripping rate related information, oil filling equipment related information, instrument related information, instrument process parameters, personnel configuration information, and detection process data records.

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