Solid level gauge suitable for high-temperature, high-pressure and corrosive environment and measuring method

Abstract

The invention belongs to the field of material level measurement, particularly relates to a solid level gauge suitable for a high-temperature, high-pressure and corrosive environment and a measurement method, and aims to solve the problems of inaccurate measurement and poor reliability under severe working conditions in the prior art. The level gage comprises a sealed cabin body, a cooling section connected to the lower end of the sealed cabin body, a lifting driving mechanism installed at the upper end of the sealed cabin body and a probe rod with one end connected with the lifting driving mechanism, and the other end of the probe rod is connected with a probe with a built-in pressure sensor. During measurement, the lifting driving mechanism drives the probe rod and the probe to extend into the working condition equipment to descend; when the probe contacts with the surface of the material, the pressure sensor generates a trigger signal, and the control system records the current position and converts the current position into the height of the material level. By arranging the cooling section and the sealed cabin body, high-temperature, high-pressure and corrosive environments are effectively handled, continuous contact between measurement parts and severe environments is avoided, and the measurement precision and the reliability of long-term operation of equipment are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the field of level measurement, specifically relating to a solid level gauge and measurement method suitable for high temperature, high pressure and corrosive environments. Background Technology

[0002] In industrial production fields such as coal chemical, cement, metallurgy, and power, accurate and stable measurement of the level of solid materials (such as coal powder, mineral powder, ash, etc.) in storage containers is a key link to ensure smooth production processes and safe operation.

[0003] Currently, commonly used solid material level measurement equipment in industry mainly includes radar level gauges and plumb bob level gauges. However, both types of level gauges exhibit significant limitations under harsh working conditions such as high temperature, high pressure, strong corrosion, or high dust levels. The electromagnetic wave signal of radar level gauges is easily affected by diffraction and absorption by dust in the silo, leading to signal attenuation or even loss. Simultaneously, uneven surfaces and the presence of corners in solid materials can cause diffuse reflection, severely affecting measurement accuracy. Furthermore, the antenna and waveguide components of radar level gauges are easily damaged in high temperature, high pressure, or corrosive media, and the equipment is expensive and complex to install and debug.

[0004] As a contact-type measuring device, the weighted level gauge's structure is primarily based on mechanical transmission. In practical applications, vibrations in the plant or silo can easily cause the steel belt or wire rope to shake, leading to measurement errors or even rope tangling. The weight can also easily become stuck in soft materials, resulting in inflated readings. More seriously, in high-temperature environments, its motor and transmission mechanism are prone to burnout; high-pressure environments pose a significant challenge to its shaft seal; and dust can easily jam the transmission mechanism, leading to rapid wear, high failure rates, and poor reliability.

[0005] Therefore, there is an urgent need for a solid material level measuring device that can overcome the above-mentioned defects and achieve long-term stable and accurate measurement in extreme industrial environments such as high temperature, high pressure and strong corrosion. Summary of the Invention

[0006] In order to solve the above-mentioned problems in the prior art, namely the problems of inaccurate measurement and poor reliability under harsh working conditions, the present invention provides a solid level gauge and measurement method suitable for high temperature, high pressure and corrosive environments.

[0007] The first embodiment of the present invention proposes a solid level gauge suitable for high temperature, high pressure and corrosive environments, comprising:

[0008] Sealed compartment; A cooling section is connected to the lower end of the sealed chamber, and the cooling section is used to connect to the equipment under the condition to be measured. A lifting drive mechanism is installed at the upper end of the sealed chamber and is sealed to the sealed chamber. The probe has one end connected to the lifting drive mechanism to be driven to lift. A probe is connected to the other end of the probe rod, and a pressure sensor is installed inside the probe; The probe passes through the inner cavity of the cooling section, so that the probe can be driven by the lifting drive mechanism to extend into or retract into the working equipment.

[0009] Furthermore, the lifting drive mechanism includes a servo motor, a reducer, and a hoisting mechanism that are connected in sequence. One end of the probe passes through the sealed chamber and is connected to the winch mechanism so that it can be driven to rise and fall by the winch mechanism.

[0010] Furthermore, it also includes a control system, which is electrically connected to the servo motor and is used to control the operation of the servo motor according to the feedback signal of the pressure sensor, so as to adjust the lifting speed and position of the probe.

[0011] Furthermore, the upper end of the sealed chamber is provided with an upper flange for sealing connection with the outer shell of the hoisting mechanism, and the lower end of the sealed chamber is provided with a lower flange for sealing connection with the cooling section.

[0012] Furthermore, the cooling section includes an inner tube and an outer tube arranged coaxially; A jacketed cavity for the flow of cooling medium is defined between the inner tube and the outer tube; the inner tube defines a central channel through which the probe passes; the outer tube is provided with a cooling medium inlet and a cooling medium outlet that are in fluid communication with the jacketed cavity.

[0013] Furthermore, the probe and / or the probe rod are made of high-temperature and corrosion-resistant materials.

[0014] Furthermore, the high-temperature and corrosion-resistant material is 310S stainless steel or a special alloy.

[0015] Furthermore, a magnetohydrodynamic seal is provided on the top of the upper flange or the sealed chamber, and the output end of the hoisting mechanism extends into the interior of the sealed chamber through the magnetohydrodynamic seal.

[0016] Furthermore, the probe is a columnar component with internal telescopic properties.

[0017] The second embodiment of the present invention proposes a solid material level measurement method suitable for high temperature, high pressure and corrosive environments. Based on a solid material level gauge suitable for high temperature, high pressure and corrosive environments, the method includes: Cooling medium is introduced into the jacket cavity of the cooling section, and the sealed chamber is sealed and pressurized so that its internal pressure is adapted to or higher than the pressure inside the working equipment. The control system drives the lifting drive mechanism, which releases the probe rod and probe downward through the winch mechanism and extends them into the working equipment; When the probe comes into contact with the material, its internal pressure sensor generates a trigger signal and feeds it back to the control system; The control system immediately records the length of the probe as it is lowered or the number of rotations of the winch mechanism and converts it into the current material level height. After the position recording is completed, the control system immediately drives the lifting drive mechanism to reverse, retracting the probe and probe rod, so that the probe is no longer in continuous contact with the material and the high temperature and high pressure environment.

[0018] The beneficial effects of this invention are: This invention significantly enhances the adaptability and survivability of solid level gauges in extreme industrial environments. By incorporating a jacketed cooling section, core control components such as the lifting drive mechanism are effectively isolated from high-temperature areas, thus solving the problem of easy damage to motors and electronic components in traditional level gauges at high temperatures. Simultaneously, by employing an integrally sealed chamber, supplemented by flanges and magnetohydrodynamic seals, a high-pressure-resistant, sealed space is constructed, effectively addressing the stringent challenges to equipment sealing under high-pressure conditions. Furthermore, the probe and sensor are made of special high-temperature and corrosion-resistant materials, fundamentally solving the problem of measurement components being corroded in corrosive materials. This structural combination design enables the invention to operate stably for extended periods in harsh environments with high temperature, high pressure, and strong corrosion.

[0019] This invention significantly improves the accuracy and long-term reliability of solid material level measurement. It employs a direct-contact measurement principle with a built-in pressure sensor in the probe. A precise trigger signal is obtained when the probe contacts the material surface. This method is unaffected by factors such as dust, steam, material pile angle, or changes in dielectric constant within the storage chamber, overcoming the accuracy degradation problem caused by signal attenuation or diffuse reflection in radar level gauges. More importantly, this invention adopts a "descend during measurement, retract during non-measurement" working mode, ensuring that the probe only contacts the material and harsh environment for a brief moment during measurement before retracting to the cooling zone's protection area. This intermittent working mode greatly reduces wear, corrosion, and material buildup risks on the probe and probe rod, avoiding the jamming, wear, and frequent malfunctions caused by long-term exposure of mechanical components in hammer level gauges. This significantly extends the equipment's service life and maintenance cycle, ensuring long-term measurement reliability.

[0020] This invention automates and automates the measurement process while reducing overall operating costs. Through a closed-loop control system comprised of a control system, servo motor, and pressure sensor, fully automated unattended operation throughout the measurement cycle is achieved. The system precisely controls the probe's lifting speed and position, preventing impact on materials. The control system can also record and analyze historical data, enhancing the level of intelligent management. Compared to expensive high-frequency radar systems, the core sensing components of this invention are less expensive. Compared to the frequently maintained weighted level gauge, this invention significantly reduces maintenance costs and production downtime losses due to equipment failure due to its high reliability, resulting in greater economic benefits. Attached Figure Description

[0021] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a structural diagram of a solid level gauge suitable for high temperature, high pressure and corrosive environments according to the present invention; The components include: sealed chamber 10, upper flange 11, lower flange 12, magnetohydrodynamic seal 13, cooling section 20, inner pipe 21, outer pipe 22, jacket cavity 23, cooling medium inlet 25, cooling medium outlet 26, lifting drive mechanism 30, servo motor 31, reducer 32, hoisting mechanism 33, probe rod 40, and probe 50. Detailed Implementation

[0022] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0023] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] like Figure 1 As shown, the first embodiment of the present invention proposes a solid level gauge suitable for high temperature, high pressure and corrosive environments, comprising: Sealed compartment 10; Cooling section 20 is connected to the lower end of the sealed chamber 10, and the cooling section 20 is used to connect to the working condition equipment to be measured. The lifting drive mechanism 30 is installed at the upper end of the sealed chamber 10 and is sealed to the sealed chamber 10. The probe 40 has one end connected to the lifting drive mechanism 30 so as to be driven to lift. The probe 50 is connected to the other end of the probe rod 40, and a pressure sensor is provided inside the probe 50; The probe 40 passes through the inner cavity of the cooling section 20, so that the probe 50 can be driven by the lifting drive mechanism 30 to extend into or retract into the working equipment.

[0025] In this embodiment, the solid level gauge, through its functional partitioned structural design, forms an integrated measurement system that can be effectively isolated from harsh working conditions. In this implementation, the high-temperature and high-pressure environment is defined as: temperature greater than 800℃ and pressure greater than 1.0 MPa.

[0026] The sealed chamber 10, as a cylindrical pressure vessel, houses and protects the core transmission components. Its robust sealing structure completely isolates these precision components from the external atmosphere and the working environment below. The cooling section 20 is a key transitional component connecting the sealed chamber 10 to the equipment under test, such as a gasifier in the coal chemical industry or a preheater in the cement industry. It not only provides robust physical support, but its main function is to create a thermal barrier, preventing the high temperature of the equipment from being conducted upwards.

[0027] The lifting drive mechanism 30 is installed at the very top of the entire device, physically away from the high-temperature area, and provides power for the precise vertical reciprocating motion of the probe 40 and the probe 50. The probe 40 and the probe 50 connected to its end constitute the execution unit that directly enters the interior of the working equipment to perform measurement tasks. The pressure sensor encapsulated inside the probe 50 is the core sensing element for sensing the surface of the material.

[0028] During operation, driven by the lifting drive mechanism 30, the probe 40 can vertically pass through the interior of the sealed chamber 10 and the central channel of the cooling section 20, allowing the probe 50 at its end to accurately extend into the working equipment for material level measurement. After the measurement task is completed, it is completely retracted into the protected area of ​​the cooling section 20. This design, through effective structural isolation and clear functional zoning, constructs a basic platform capable of simultaneously coping with the challenges of high temperature, high pressure, and corrosion, making it possible to achieve accurate and reliable material level measurement and solving the fundamental problem of poor adaptability of existing technologies under harsh working conditions.

[0029] As a further explanation of the present invention, the lifting drive mechanism 30 includes a servo motor 31, a reducer 32 and a hoisting mechanism 33 connected in sequence; one end of the probe 40 passes through the sealed chamber 10 and is connected to the hoisting mechanism 33 so as to be driven to lift by the hoisting mechanism 33.

[0030] In this embodiment, to achieve precise control over the lifting speed and position of the probe rod 40, the lifting drive mechanism 30 employs a high-precision power and transmission combination. Specifically, the servo motor 31 is chosen as the power source due to its advantages of fast response speed and high control precision. The output shaft of the servo motor 31 is connected to the reducer 32. The reducer 32 reduces the rotational speed and significantly increases the output torque, thereby providing a stable and powerful driving force for lifting or lowering the probe rod 40 and probe 50, which carry a certain weight. The output end of the reducer 32 is connected to the winch mechanism 33, which can be a precision winch or drum, directly fixedly connected to the upper end of the probe rod 40. The probe rod 40 can be designed as a flexible steel strip, steel wire rope, or a rigid rod with internal telescopic properties. When the servo motor 31 receives a control command to rotate forward or reverse, the power is transmitted through the reducer 32, driving the winch mechanism 33 to correspondingly wind up or release the probe rod 40, thereby enabling the probe rod 40 to achieve smooth and precise vertical lifting and lowering motion. This drive chain, consisting of a servo motor, reducer, and hoisting mechanism, ensures the controllability of the probe 50's descent speed and the accuracy of its position during the measurement process. This provides a reliable foundation for subsequent precise calculation of the material level based on displacement data, thereby improving the measurement accuracy.

[0031] As a further explanation of the invention, it also includes a control system, which is electrically connected to the servo motor 31 and is used to control the operation of the servo motor 31 according to the feedback signal of the pressure sensor, so as to adjust the lifting speed and position of the probe 40.

[0032] Specifically, this invention is equipped with an intelligent control system, which can be set in a remote computer or dedicated controller and electrically connected to the driver of the servo motor 31 via a control cable. Before measurement begins, the operator can set the measurement program and related parameters through the control system interface on the computer. During the measurement process, the control system not only sends commands to the servo motor 31 to drive it to operate at a preset speed to lower the probe 50, but also receives feedback signals from the pressure sensor inside the probe 50 in real time at high frequency.

[0033] When the tip of probe 50 contacts the surface of the solid material, the supporting force of the material immediately causes a sudden change in the output signal of the pressure sensor or reaches a preset pressure threshold. Once the control system detects this trigger signal, it immediately sends a stop command to the driver of servo motor 31 and accurately records the total number of rotations of the servo motor or the encoder reading at this moment. This data directly corresponds to the length of the probe rod 40 that has been lowered. Subsequently, the control system issues a reverse command, driving servo motor 31 to retract probe rod 40 and probe 50 to a safe position. This closed-loop control mechanism based on pressure signal feedback achieves full automation of the measurement process, ensuring not only the instantaneous and accurate capture of the material surface position but also avoiding measurement errors caused by the probe penetrating too deeply into soft materials.

[0034] As a further explanation of the present invention, the upper end of the sealed chamber 10 is provided with an upper flange 11 for sealing connection with the outer shell of the hoisting mechanism 33, and the lower end of the sealed chamber 10 is provided with a lower flange 12 for sealing connection with the cooling section 20.

[0035] To ensure the sealing and structural stability of the entire device, standard flange connections are used between the main components in this embodiment. Specifically, the sealed chamber 10, which serves as a pressure vessel, has an upper flange 11 machined at its top opening. The base or outer shell of the hoisting mechanism 33 in the lifting drive mechanism 30 also has a matching flange face. The two are fastened together with a ring of high-strength bolts, and a high-pressure resistant gasket is sandwiched between the flange contact surfaces to achieve a reliable sealing connection. Similarly, a lower flange 12 is provided at the bottom opening of the sealed chamber 10. This lower flange 12 mates with the flange at the upper end of the cooling section 20, achieving a sealing connection in the same manner. This mature flange connection method not only provides strong mechanical fixing force to withstand the high pressure inside the equipment but also ensures the sealing reliability of the connection, effectively preventing high-pressure gas or harmful dust from leaking into the lifting drive mechanism or the external environment. It also facilitates on-site installation, disassembly, and maintenance of the equipment.

[0036] As a further explanation of the present invention, the cooling section 20 includes an inner tube 21 and an outer tube 22 arranged coaxially; a jacket cavity 23 for the flow of cooling medium is defined between the inner tube 21 and the outer tube 22; the inner tube 21 defines a central channel through which the probe 40 passes; and the outer tube 22 is provided with a cooling medium inlet 25 and a cooling medium outlet 26 that are in fluid communication with the jacket cavity 23.

[0037] To effectively handle operating temperatures as high as 800℃ or even higher, the cooling section 20 is designed as a highly efficient jacketed heat exchange structure. The cooling section 20 consists of an inner tube 21 and an outer tube 22 coaxially sleeved around it. The inner wall of the inner tube 21 defines a smooth and unobstructed central channel, allowing the probe 40 to pass through it vertically without obstruction. An annular, closed jacket cavity 23 is formed between the outer wall of the inner tube 21 and the inner wall of the outer tube 22. Cooling medium inlets 25 and cooling medium outlets 26, typically located near the upper and lower ends of the outer tube 22, are respectively provided and communicate with the jacket cavity 23. During operation, cooling media such as circulating water or cooling air are pumped into the jacket cavity 23 through the cooling media inlet 25. Within the cavity, the media flows freely and exchanges heat with the outer wall of the inner tube 21, efficiently absorbing a large amount of heat conducted from the operating equipment via the connecting flange and the inner tube 21 wall. The heated cooling media then flows out through the cooling media outlet 26 and is sent to the external cooling system for cooling before being recycled. This forced circulation cooling method efficiently removes heat, forming a reliable temperature barrier. This ensures that the upper sealed chamber 10 and the internal lifting drive mechanism 30 can operate normally within a safe temperature range for extended periods, solving the problem of existing technologies where motors and electronic components are easily damaged by high temperatures.

[0038] As a further explanation of the present invention, the probe 50 and / or the probe rod 40 are made of high-temperature and corrosion-resistant materials.

[0039] In this embodiment, considering that the lower parts of the probe 50 and probe rod 40 are directly exposed to one or more extreme working conditions such as high temperature, high pressure, strong corrosion, and high dust, the selection of their materials is crucial. To ensure that these core measuring components can operate stably for a long time without being physically damaged or chemically corroded, the outer shell of the probe 50 and the probe rod 40 are both made of special high-temperature and corrosion-resistant materials. This material must be able to maintain sufficient mechanical strength, oxidation resistance, and creep resistance at the target operating temperature, such as above 800°C, while also having excellent chemical resistance to corrosive gases or materials such as sulfur compounds and chlorides present in the working conditions. Manufacturing with such special materials can directly resist physical wear and chemical corrosion in harsh environments, which is one of the fundamental measures to ensure the long-term reliability and measurement accuracy of the equipment, thereby avoiding measurement interruptions and equipment damage due to material failure.

[0040] As a further explanation of the present invention, the high-temperature and corrosion-resistant material is 310S stainless steel or a special alloy.

[0041] As a specific implementation of the above technical solution, the housing of the probe 50 and the probe rod 40 can be made of 310S stainless steel. This is an austenitic chromium-nickel stainless steel. Due to its high percentage of chromium and nickel, it has excellent oxidation resistance, corrosion resistance, and excellent high-temperature strength and creep strength, enabling continuous operation at high temperatures. In more severe corrosive environments, higher-grade special alloys, such as Hastelloy or Inconel, can also be selected. The specific material selection will be flexibly determined based on actual working conditions, such as the maximum temperature, pressure rating, and the specific chemical composition of the material. For example, in an environment rich in highly corrosive gases such as hydrogen sulfide in a coal chemical gasifier, a special alloy with stronger sulfur corrosion resistance would be a better choice. This targeted material selection strategy gives the level gauge of this invention broad applicability to various working conditions and can fundamentally solve the corrosion problem.

[0042] As a further explanation of the present invention, a magnetohydrodynamic seal 13 is provided on the top of the upper flange 11 or the sealing chamber 10, and the output end of the hoisting mechanism 33 extends into the interior of the sealing chamber 10 through the magnetohydrodynamic seal 13.

[0043] To overcome the challenge of dynamic sealing of rotating shafts under high pressure, this invention employs a magnetohydrodynamic seal 13 in a preferred embodiment. This seal is precisely installed at the point where the output shaft of the hoisting mechanism 33 passes through the top plate of the sealed chamber 10. Magnetohydrodynamic sealing technology utilizes a "liquid O-ring" formed by a magnetic fluid under a strong magnetic field to achieve a seal, enabling near-zero leakage high-performance sealing. Specifically, the output end of the hoisting mechanism 33 needs to extend from the external drive unit into the sealed chamber 10, where pressure can reach 1.0 MPa or even higher. This point of rotation is a weak link where traditional sealing technologies are prone to leakage. By placing the magnetohydrodynamic seal 13 at this location, when the output shaft of the hoisting mechanism rotates, the magnetic fluid is stably bound in the tiny gap between the shaft and the pole shoe under the action of the permanent magnet, forming a multi-stage sealing ring that reliably isolates the huge pressure difference between the inside and outside of the sealed chamber. Compared to traditional packing seals or mechanical seals, magnetohydrodynamic seals have the advantages of extremely low frictional torque, long service life, and excellent sealing performance, making them an ideal solution for addressing the challenges of dynamic sealing under high pressure conditions.

[0044] As a further explanation of the present invention, the probe 40 is a columnar member with internal telescopic properties.

[0045] In an optional embodiment of the invention, to reduce the overall installation height of the level gauge, especially in applications with long measuring strokes, the probe 40 can be designed as a columnar member with internal telescopic capabilities. This probe structure is similar to a multi-section sleeve antenna or a casing drill rod, consisting of multiple sections of tubing with diameters ranging from thick to thin, nested sequentially. In the retracted state, the sections are contracted together, resulting in a shorter overall length; during lowering for measurement, the sections smoothly extend sequentially under their own weight or an internal drive mechanism, achieving the desired measuring depth. This design significantly reduces the upper space required when the probe is fully retracted, meaning the height of the sealed chamber 10 can be correspondingly smaller, making the entire level gauge structure more compact. This is particularly suitable for applications with limited installation space, improving the installation flexibility of the equipment.

[0046] The second embodiment of the present invention proposes a solid level measurement method suitable for high temperature, high pressure and corrosive environments. Based on the solid level gauge suitable for high temperature, high pressure and corrosive environments described in the first embodiment, the method includes: Cooling medium is introduced into the jacket cavity 23 of the cooling section 20, and the sealed chamber 10 is sealed and pressurized so that its internal pressure is adapted to or higher than the pressure inside the working equipment. The control system drives the lifting drive mechanism 30, and releases the probe rod 40 and probe 50 downward through the winch mechanism 33, so that they extend into the working equipment. When the probe 50 comes into contact with the material, its internal pressure sensor generates a trigger signal and feeds it back to the control system; The control system immediately records the length of the probe 40 when it is lowered or the number of rotations of the winch mechanism 33, and converts it into the current material level height. After the position recording is completed, the control system immediately drives the lifting drive mechanism 30 to reverse, retracting the probe 50 and probe rod 40 into the protection range of the sealed chamber 10 and cooling section 20, so that the probe 50 is removed from continuous contact with the material and the high temperature and high pressure environment.

[0047] This invention provides a specific, automated operating procedure. Before performing the measurement task, preparatory work is first performed: Start the cooling system to ensure that the cooling medium, such as circulating water, flows stably through the jacket cavity 23 of the cooling section 20. At the same time, if there is pressure inside the working equipment, the sealed chamber 10 needs to be pre-pressurized to balance or slightly increase its internal pressure with the working pressure. This can effectively prevent dust or gas from flowing back into the equipment.

[0048] Once ready, the control system, including the host computer software, issues measurement commands to initiate a standard measurement sequence. First, the control system drives the servo motor 31, which, through the reducer 32 and hoisting mechanism 33, releases the probe rod 40 and probe 50 downwards at a preset, smooth speed. During descent, the control system monitors the baseline signal of the pressure sensor at a low frequency for fault diagnosis. When the tip of probe 50 touches the surface of the solid material, the supporting force of the material causes pressure on probe 50. This pressure is converted into an electrical signal by an internal pressure sensor (e.g., the Ocean Micro Pressure Sensor DYLY-108, whose range can be flexibly set from 0 to 10000 Newtons depending on the material properties). Once this signal change is detected by the control system, it immediately determines that the material surface has been reached.

[0049] At this point, the system accurately records the displacement data from the initial reference point to the current position. This data can be precisely calculated using the encoder pulse count of the servo motor, and then converted into the actual material level height by combining preset parameters such as the equipment installation height. After data recording is complete, the system will enter the retraction program without delay, driving the lifting drive mechanism 30 to rotate in reverse at high speed, lifting the probe 50 and probe rod 40 to a protected standby position. Thus, a complete, automated closed-loop measurement cycle is completed. This "measure and go" working mode is key to the reliability of this invention. It minimizes the contact time between the measuring components and the harsh environment, greatly improving the reliability and service life of the equipment, and avoiding the wear, jamming, and corrosion problems caused by long-term exposure of traditional instruments.

[0050] The third embodiment of this invention proposes a solid material level measurement method suitable for high temperature, high pressure, and corrosive environments. Based on the second embodiment, the control system drives the lifting drive mechanism, and the hoisting mechanism releases the probe and sensor downwards, extending them into the working equipment. The specific steps include a multi-stage adaptive descent and precise material contact determination process. Upon receiving the measurement command, the control system first drives the probe to descend at a first preset speed; During the descent, the control system monitors the pressure signal collected by the pressure sensor in real time and performs the first stage judgment: calculates the real-time rate of change of the pressure signal and determines whether the pressure signal exhibits continuous fluctuations exceeding a preset fluctuation threshold. If the first stage determination is successful, or if the probe has descended to the preset safe switching height based on historical material level data, the control system will switch the probe's descent speed to a second preset speed lower than the first preset speed, and enter the precision measurement descent stage. During the precise descent phase, the control system performs a second-stage determination to confirm effective contact with the material surface. This second-stage determination is a composite logic judgment, and effective contact is determined only if all three of the following conditions are met simultaneously: (1) The instantaneous value of the pressure signal is greater than the first preset pressure threshold; (2) The real-time rate of change of the pressure signal is greater than the preset rate of change threshold; (3) The duration of the state where conditions (1) and (2) are met simultaneously is greater than the first preset time threshold.

[0051] The method also includes integrated obstacle handling and system self-learning steps: During the entire process of probe descent, the control system performs obstacle monitoring in parallel. If the instantaneous value of the pressure signal exceeds a second preset pressure threshold that is much greater than the first preset pressure threshold before reaching the expected material level height range, the control system immediately interrupts the descent and starts a trial procedure. The trial procedure includes controlling the probe to rise by a preset retraction distance, waiting, and then attempting to descend again. If the second preset pressure threshold is repeatedly triggered within the same height range and the number of retries reaches a preset maximum value, it is determined that there is a fixed obstacle, the measurement is terminated, the probe is retracted, and an alarm is triggered. The control system records the height of the triggered obstacle as the risk position. In subsequent measurement cycles, when the probe descends to near the risk position, it automatically adopts the second preset speed or a lower descent speed and increases the signal sampling frequency. Meanwhile, the control system records the material level height of each successful measurement and dynamically updates the safety switching height and the expected material level height range based on historical data.

[0052] In this embodiment, after the control system receives the measurement start command from the host computer or timer, it first enters the rapid descent phase. The controller sends a command to the servo driver to drive the servo motor at a set first preset speed. run. Typically, the descent speed is set to 80%-90% of the equipment's maximum safe descent speed, such as 0.8 m / s. The purpose is to quickly traverse the upper cavity of the hopper without impacting the material, thus shortening the measurement cycle. During this stage, the control system samples the raw signal from the pressure sensor at a frequency f1 (e.g., 10 Hz). The signal is converted from analog to digital and calibrated to obtain the real-time pressure value. The calibration formula is: ,in Let C be the sensor sensitivity coefficient, and C be the zero-point offset compensation value. Simultaneously, the system calculates the real-time rate of change of the pressure signal. Since the sampled signal is discrete, the instantaneous rate of change is approximated using the first-order backward difference method. ,in .

[0053] Next, the system performs the first-stage judgment to decide whether to switch from rapid descent to precise descent. In this first-stage judgment, the control system monitors two conditions in parallel. The first condition is signal fluctuation prediction: the system calculates the standard deviation of the pressure signal from the most recent N sampling points (e.g., N=5, corresponding to 0.5-second data points). .like (If a preset fluctuation threshold is set, such as 15 N), then an abnormal continuous fluctuation in the pressure signal is determined. This usually indicates that the probe has approached the dusty area of ​​the material surface or the surface of loose material. The second condition is location prediction: The system calculates the probe's current height in real time. ( , To install the zero point height, (This refers to the length already lowered), and the average material level from the most recent M successful measurements is obtained. Set a safety margin. (For example, 0.5 meters). When ≤( - When the probe enters the high warning zone where the material level may be high, the controller determines that the probe has entered the high warning zone. If either of the above two conditions is met, the controller immediately sends a command to the servo drive to switch the probe's descent speed to a significantly reduced second preset speed. . The speed is typically 0.05-0.1 m / s, designed to ensure that the probe contacts the material in a gentle and controllable manner, avoiding excessive insertion into the material or impact on the probe due to excessive speed.

[0054] After entering the precision descent phase, the control system increases the sampling frequency of the pressure signal to f2 (e.g., 100 Hz) to obtain contact information with higher temporal resolution and performs the second stage of precise material contact determination. This determination employs a stringent compound logic "AND" condition. The system continuously monitors and only confirms valid material contact if the following three sub-conditions are met simultaneously: First, the instantaneous value of the pressure signal must be greater than a first preset pressure threshold, i.e. . Based on material properties and probe structure presets, typical values ​​are 100-300 N. Secondly, the real-time rate of change of the pressure signal must be greater than a preset rate of change threshold, i.e. . A typical value is 300-800 N / s; this condition is used to capture the "step" characteristic of the force at the moment of contact. Finally, both of the above conditions must be met simultaneously, and this state must persist for more than the first time threshold. (For example, 0.05-0.15 seconds) to resist transient interference. When the composite condition is met and the effective material contact is determined, the control system immediately latches the cumulative number of pulses of the servo motor encoder at this moment. Material level height Through formula The calculation shows that, among which The probe lowering length (mm / pulse) corresponds to each pulse. The calculation results are uploaded via the communication interface.

[0055] Throughout the probe's descent, the control system independently runs a high-priority obstacle monitoring thread. If a pressure signal... satisfy ( much greater than The second preset pressure threshold (e.g., 800-1500 N), and at this time the probe height If the material level is significantly higher than the expected range, an obstacle warning will be immediately triggered and the descent process will be interrupted. The system will then initiate a probe procedure: first, the probe will be raised a preset distance. (e.g., 50mm), wait (For example, 1 second) then The speed attempts to decrease. If the obstacle threshold is repeatedly triggered within the same height range and the number of retries reaches the preset maximum value, the speed will decrease. (For example, 3 times), then it will be determined as "an insurmountable fixed obstacle". The controller will terminate the measurement, retract the probe, and generate a data set including the obstacle height. Upload fault information.

[0056] At the same time, the system possesses self-learning and adaptive adjustment capabilities. The system will confirm the height of obstacles. The data is recorded in the "Risk Location List." In all subsequent measurement cycles, when the probe descends close to this risk location, the control system automatically switches to a lower descent speed and increases the signal sampling frequency to ensure cautious passage. Furthermore, the control system maintains a cyclical historical level database, updating the data after each successful measurement. The system periodically and dynamically calculates and updates the speed switching parameters based on the latest historical data. and The system also includes a target material level range for assisting in obstacle detection, enabling the entire control logic to adaptively optimize in response to changes in the production process, thereby further improving the robustness and long-term reliability of the measurement.

[0057] Through the above specific implementation methods, the control method of the present invention deeply integrates intelligent decision-making, safety protection and self-learning capabilities, forming a complete, robust and continuously optimized solution for solid material level measurement under high temperature, high pressure and corrosive environment.

[0058] This embodiment fundamentally changes the interaction mode between the measuring component and the harsh environment by introducing a highly intelligent closed-loop control logic. Its core lies in transforming the traditional "continuous detection" or "simple triggering" into a controlled process of "intelligent prediction, precise contact, and instantaneous retraction." Specifically, based on real-time pressure signals and historical data, the control system autonomously decides and switches between high-speed and low-speed modes during the probe's descent. This not only significantly improves the efficiency of a single measurement but, more importantly, ensures that the probe contacts the material surface in the gentlest way. This precise speed control effectively avoids impact insertion of the probe into the material or mechanical impact on the probe itself, directly overcoming the inherent problems of large measurement errors and rapid mechanical wear caused by impact and vibration in hammer-type level gauges.

[0059] Furthermore, the precise material contact determination algorithm defined in this embodiment requires that three conditions—the instantaneous value of the pressure signal, its rate of change, and its duration—be satisfied simultaneously, forming a highly reliable identification filter. This composite logic judgment mechanism can extremely accurately distinguish between genuine material contact and instantaneous interference signals caused by dust, airflow disturbances, or material collapse within the silo. This precisely compensates for the poor anti-interference capability of radar level gauges due to diffuse reflection and signal attenuation, enabling the present invention to obtain stable and accurate level signals even in dusty working conditions, significantly improving the accuracy and reliability of the measurement.

[0060] When faced with complex situations such as arching, clumping, or detached lining plates within the storage chamber, as mentioned in the background technology, the obstacle monitoring and probing program integrated in this embodiment demonstrates excellent fault tolerance and self-protection capabilities. The system can immediately stop and initiate a probing cycle when the probe accidentally touches a hard foreign object, rather than forcibly passing through and causing equipment jamming or damage. This intelligent fault prediction and handling mechanism completely solves the safety hazards of the steel wire rope easily becoming tangled and the weight easily getting stuck in the weight-type level gauge, transforming the risk of potential equipment downtime into a manageable alarm event, greatly enhancing the system's survivability and operational continuity under non-ideal working conditions.

[0061] Finally, the system's self-learning and dynamic parameter updating capabilities in this embodiment endow the equipment with long-term adaptability and optimization potential. By continuously absorbing historical measurement data, the system can automatically adjust the speed switching point and the expected material level range, ensuring that the control strategy remains synchronized with actual material characteristics and process changes. This feature enables the present invention to gradually optimize its measurement behavior, reduce operational errors, and decrease reliance on manual parameter tuning, thereby fundamentally addressing the challenges of complex debugging, frequent maintenance, and declining long-term reliability due to changes in operating conditions in existing equipment, as described in the background art.

[0062] The terms “first”, “second”, etc., are used to distinguish similar objects, not to describe or indicate a specific order or sequence.

[0063] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0064] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A solid level gauge suitable for high temperature, high pressure, and corrosive environments, characterized in that, include: Sealed compartment (10); A cooling section (20) is connected to the lower end of the sealed chamber (10), and the cooling section (20) is used to connect to the working condition equipment to be measured; A lifting drive mechanism (30) is installed at the upper end of the sealed chamber (10) and is sealed to the sealed chamber (10); The probe (40) is connected at one end to the lifting drive mechanism (30) so as to be driven to lift. A probe (50) is connected to the other end of the probe rod (40), and a pressure sensor is provided inside the probe (50); The probe (40) passes through the inner cavity of the cooling section (20) so that the probe (50) can be driven by the lifting drive mechanism (30) to extend into or retract into the working equipment.

2. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 1, characterized in that, The lifting drive mechanism (30) includes a servo motor (31), a reducer (32) and a hoisting mechanism (33) connected in sequence. One end of the probe (40) passes through the sealed chamber (10) and is connected to the hoisting mechanism (33) so that it can be driven to rise and fall by the hoisting mechanism (33).

3. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 2, characterized in that, It also includes a control system, which is electrically connected to the servo motor (31) and is used to control the operation of the servo motor (31) according to the feedback signal of the pressure sensor, so as to adjust the lifting speed and position of the probe (40).

4. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 2, characterized in that, The upper end of the sealed chamber (10) is provided with an upper flange (11) for sealing connection with the outer shell of the hoisting mechanism (33), and the lower end of the sealed chamber (10) is provided with a lower flange (12) for sealing connection with the cooling section (20).

5. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 1, characterized in that, The cooling section (20) includes an inner tube (21) and an outer tube (22) arranged coaxially; A jacketed cavity (23) for the flow of cooling medium is defined between the inner tube (21) and the outer tube (22); the inner tube (21) defines a central channel through which the probe (40) passes; the outer tube (22) is provided with a cooling medium inlet (25) and a cooling medium outlet (26) in fluid communication with the jacketed cavity (23).

6. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 1, characterized in that, The probe (50) and / or the probe rod (40) are made of high-temperature and corrosion-resistant materials.

7. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 6, characterized in that, The high-temperature and corrosion-resistant material is 310S stainless steel or a special alloy.

8. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 4, characterized in that, A magnetohydrodynamic seal (13) is provided on the top of the upper flange (11) or the sealed chamber (10), and the output end of the hoisting mechanism (33) extends into the interior of the sealed chamber (10) through the magnetohydrodynamic seal (13).

9. A solid level gauge suitable for high temperature, high pressure, and corrosive environments according to claim 1, characterized in that, The probe (40) is a columnar component with internal telescopic properties.

10. A method for measuring solid material level in high-temperature, high-pressure, and corrosive environments, based on a solid material level gauge suitable for high-temperature, high-pressure, and corrosive environments as described in any one of claims 1-9, characterized in that... The method includes: Cooling medium is introduced into the jacket cavity (23) of the cooling section (20), and the sealed chamber (10) is sealed and pressurized so that its internal pressure is adapted to or higher than the pressure inside the working equipment. The control system drives the lifting drive mechanism (30), and releases the probe rod (40) and probe (50) downward through the winch mechanism (33) and extends them into the working equipment; When the probe (50) comes into contact with the material, the pressure sensor inside it generates a trigger signal and feeds it back to the control system; The control system immediately records the length of the probe (40) as it is lowered or the number of rotations of the winch mechanism (33), and converts it into the current material level height. After recording the current material level height, the control system immediately drives the lifting drive mechanism (30) to reverse, retracting the probe (50) and probe rod (40) so that the probe (50) is no longer in continuous contact with the material and the high temperature and high pressure environment.

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