High-reliability and high-precision pressure sensor and preparation process

Abstract

The invention relates to the field of pressure detection equipment, and discloses a high-reliability and high-precision pressure sensor and a preparation process thereof, the high-reliability and high-precision pressure sensor comprises a main body, main body countersunk head mounting grooves are formed in four corners of the surface of the main body, mounting screws penetrate through the main body countersunk head mounting grooves of the main body, and the mounting screws extend out of the main body; the upper end of the main body is opened and provided with a positioning groove, a force measuring core module is arranged at the positioning groove on the inner side of the main body, and leveling auxiliary modules are arranged in the main body corresponding to two sides of the force measuring core module. According to the invention, the sensor is provided with an autonomous leveling structure, and is suitable for installation and use in multiple scenes: the sensor is internally provided with a symmetrical double-shear-fork leveling auxiliary module, and a hydraulic driving telescopic rod is matched with a lifting hydraulic cylinder, so that autonomous horizontal correction of the force measurement core module can be realized, and even if inclination and deviation occur on a non-horizontal mounting surface and during operation, the force measurement core module can be rapidly adjusted to a horizontal state; the detection precision is further guaranteed, and the installation and debugging difficulty is reduced.

Description

Technical Field

[0001] This invention relates to the field of pressure detection equipment, and in particular to a high-reliability, high-precision pressure sensor and its manufacturing process. Background Technology

[0002] Pressure sensors are core components in industrial measurement and control and precision metrology. They are mainly used to convert external pressure signals into collectable electrical signals and are widely used in automated production lines, precision instruments, engineering machinery and other scenarios. As the industry's requirements for detection accuracy and operational stability continue to increase, existing conventional pressure sensors have gradually exposed many technical defects and are unable to meet the needs of high precision and high reliability.

[0003] Currently, traditional pressure sensors generally suffer from the following technical drawbacks: The core force-measuring component is prone to eccentricity; once the pressure transmission path deviates, force measurement deviations are easily observed, resulting in low overall detection accuracy. Furthermore, after long-term use, zero-point drift becomes significant, making them unsuitable for precision detection scenarios. The sensor lacks an independent leveling structure; when tilted or subjected to uneven force during installation or use, it cannot quickly correct its levelness, further exacerbating detection errors and reducing sensor lifespan. The protective structure is inadequate; the sensor's outer surface is susceptible to lateral impacts and collisions, while the internal sensing core is easily damaged by external forces, resulting in insufficient overall operational reliability and a lack of corresponding abnormal touch and overload warning functions. Insufficient control over component assembly precision leads to a disconnect between processing and assembly procedures, resulting in poor product consistency and significant maintenance difficulties. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a high-reliability and high-precision pressure sensor and its manufacturing process to solve the problems of low detection accuracy, easy eccentricity under force, difficulty in leveling, poor protection performance, insufficient operational reliability and poor control of manufacturing process of existing pressure sensors.

[0005] To address the aforementioned problems, the present invention is implemented through the following technical solution.

[0006] A high-reliability, high-precision pressure sensor and its manufacturing process include: a main body with countersunk mounting grooves at the four corners of its surface, each groove having a through-hole mounting screw extending outwards; a positioning groove at the top of the main body; a force-measuring core module located in the positioning groove inside the main body; leveling auxiliary modules located on both sides of the force-measuring core module inside the main body; a power supply box located on one side inside the main body; a safety protection module located on the outside of the main body; mounting grooves on the four sides of the outside of the main body, each containing an audible and visual alarm buzzer; and status indicator light strips located at the four corners of the main body. The power supply box is electrically connected to the force-measuring core module, the lateral force touch sensor, the audible and visual alarm buzzer, and the status indicator light strips, providing power to the entire component.

[0007] In one embodiment, the force measuring core module includes an upper bearing top plate, a countersunk mounting groove for the top plate, a first fastening screw, a force transmission top plate, a second fastening screw, a pressure head, a force concentration pressure point, a force-to-electricity conversion core, a countersunk mounting groove for the core, and an internal hex bolt. The cross-section of the upper bearing top plate is smaller than the positioning groove, and the top height of the upper bearing top plate is higher than the highest point of the main body.

[0008] In one embodiment, a countersunk mounting groove is provided on the surface of the upper supporting top plate, and a fastening screw 1 passes through the countersunk mounting groove to connect the upper supporting top plate with the force transmission upper plate. Two fastening screws are symmetrically provided on both sides of the force transmission upper plate.

[0009] In one embodiment, the pressure head is fixed to the bottom end of the force transmission plate, the force concentration pressure point is located at the center of the bottom end of the pressure head, the force-to-electric conversion core is located directly below the force concentration pressure point, and the surface of the force-to-electric conversion core is provided with annular countersunk mounting grooves at equal intervals. Hexagonal socket bolts are assembled inside the countersunk mounting grooves. The force concentration pressure point adopts a conical solid boss structure, and the center of the force concentration pressure point is coaxially arranged with the pressure head, the force-to-electric conversion core, and the force center.

[0010] In one embodiment, the leveling auxiliary module includes a module connection panel, a panel connection threaded hole, a lower bearing base plate, a scissor lift arm, a hydraulically driven telescopic rod, and a lifting hydraulic cylinder. The module connection panel has a panel connection threaded hole at the position corresponding to the second fastening screw. The module connection panel is fixedly connected to the bottom end of the force transmission upper plate through the panel connection threaded hole and the second fastening screw.

[0011] In one embodiment, the top of the scissor lift arm is hinged to a module connection panel, the bottom is hinged to a lower support plate, the lifting hydraulic cylinder is driven by a hydraulically driven telescopic rod, and the end of the hydraulically driven telescopic rod away from the lifting hydraulic cylinder is connected to the module connection panel.

[0012] In one embodiment, the scissor lift arm adopts a symmetrical double scissor structure, with the hydraulically driven telescopic rod and the lifting hydraulic cylinder symmetrically arranged along the central axis of the scissor lift arm.

[0013] In one embodiment, the safety protection module includes a protective strip, a built-in hollow tube, a lateral force touch sensor, and an impact buffer strip. The protective strip covers the outer edge of the main body, the built-in hollow tube is embedded inside the protective strip, and the lateral force touch sensor is provided inside the built-in hollow tube.

[0014] In one embodiment, multiple lateral force touch sensors are provided, and the multiple lateral force touch sensors are evenly distributed inside the built-in hollow tube. Two impact buffer strips are provided between the built-in hollow tube and the protective strip, and the two impact buffer strips are V-shaped.

[0015] A fabrication process for a high-reliability, high-precision pressure sensor includes the following steps: S1: Substrate pretreatment and main body forming. High-strength corrosion-resistant alloy substrate is selected. The main body is formed by precision forging and CNC machining. The countersunk mounting groove, positioning groove and outer mounting groove of the main body are machined simultaneously. The inner wall of the main body and the contact surface of the positioning groove are mirror polished to control the surface roughness ≤0.8μm and remove machining burrs and internal stress. S2: Precision machining and calibration of core force measuring components. The pressure head and the force concentration point of the conical solid structure are machined using an integrated precision turning process to ensure that the coaxiality error of the pressure head, the force concentration point and the force conversion core is ≤0.02mm. The force conversion core is patched, temperature drift calibrated and zero point calibrated, and a countersunk mounting groove for the core is machined to ensure that the flatness of the force conversion core meets the standard. S3: Leveling auxiliary module assembly and debugging. The module connection panel, lower bearing base plate, and scissor lifting arm are processed in sequence. The hydraulic drive telescopic rod, lifting hydraulic cylinder and scissor lifting arm are precisely hinged to form a double scissor leveling structure. The stroke and lifting accuracy of the lifting hydraulic cylinder are pre-adjusted to ensure that the module connection panel is level and lifted without deviation. S4: Precise assembly of core components. Fix the qualified leveling auxiliary module to the corresponding position inside the main body. Lock the force transmission plate to the module connection panel through fastening screw two and panel connection threaded holes. Then, firmly connect the upper bearing plate to the force transmission plate through fastening screw one. The force-electric conversion core is fixed to the position of the force concentration pressure point inside the main body through internal hex bolts. The assembly torque is controlled to be consistent throughout the process. S5: Electrical module integration wiring, fixing the power supply box in the preset position inside the main body, completing the wiring welding and sealing of the power supply box and the force measurement core module, lateral force touch sensor, audible and visual alarm buzzer, status indicator light strip, and performing insulation and anti-interference treatment; S6: Safety protection module encapsulation, which integrates the built-in hollow tube with the built-in lateral force touch sensor and the V-shaped impact buffer strip into a protective strip through injection molding. The protective strip tightly wraps around the outer edge of the main body to achieve full edge enclosure protection. S7: Overall calibration and finished product inspection, power-on debugging and leveling auxiliary module, correction of the levelness of the force measurement core module, retesting of pressure accuracy, detection of lateral force touch sensitivity, verification of audible and visual alarm and status indication functions, and final fixing of mounting screws, audible and visual alarm buzzer and status indication light strip after passing the test to obtain the finished sensor.

[0016] This invention provides a high-reliability, high-precision pressure sensor and its fabrication process. Compared with existing technologies, it has the following advantages: 1. Built-in self-leveling structure, suitable for installation and use in multiple scenarios: The sensor has a built-in symmetrical double scissor leveling auxiliary module. Through the hydraulic drive telescopic rod and the lifting hydraulic cylinder, the core force measurement module can be automatically leveled. Even if it is installed on a non-horizontal surface or tilted during operation, it can be quickly adjusted to a horizontal state to ensure uniform force distribution, further guarantee detection accuracy, reduce installation and debugging difficulty, and improve scenario adaptability. 2. Based on self-leveling, a three-point coaxial force design is adopted, with the force concentration point, pressure head, and force conversion core force center completely coaxial. Combined with the force concentration point of the conical solid boss structure, it can achieve precise and concentrated transmission of external pressure, completely avoiding detection errors caused by force eccentricity and pressure dispersion. At the same time, the force conversion core is pre-calibrated for temperature drift and zero point calibration, and with high-precision assembly process, zero point drift is effectively suppressed, and the detection accuracy is stable during long-term operation, making it suitable for various high-precision force measurement scenarios. 3. Comprehensive safety protection and higher operational reliability: The main body is covered with an integrated protective strip, which, together with the V-shaped impact buffer strip, can effectively buffer lateral impact and collision forces to prevent damage to internal core components; multiple sets of built-in lateral force touch sensors can monitor abnormal external impacts and overload forces in real time, and together with the audible and visual alarm buzzer and status indicator light strip, it can realize real-time early warning of abnormalities, greatly improving the operational stability and service life of the sensors; 4. Rigorous manufacturing process and strong consistency of finished products: The entire manufacturing process, from substrate pretreatment, precision machining of core components, modular assembly to overall calibration, controls the machining accuracy and assembly torque throughout the process, optimizes process connection, and realizes standardized machining and modular assembly of core components. This can not only ensure the accuracy of individual sensors, but also achieve stable mass production and reduce the cost of later operation and maintenance and replacement. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall three-dimensional structure of a high-reliability, high-precision pressure sensor.

[0018] Figure 2 A schematic diagram of the three-dimensional structure of the high-reliability, high-precision pressure sensor body after removing the force measurement core module and the leveling auxiliary module.

[0019] Figure 3 This is a three-dimensional structural diagram of the core force measurement module and leveling auxiliary module of a high-reliability, high-precision pressure sensor.

[0020] Figure 4 This is a partial exploded structural diagram of the core force measurement module and leveling auxiliary module of a high-reliability, high-precision pressure sensor.

[0021] Figure 5 This is an exploded structural diagram of the core force measurement module for a high-reliability, high-precision pressure sensor.

[0022] Figure 6 This is a schematic diagram of the leveling auxiliary module for a high-reliability, high-precision pressure sensor.

[0023] Figure 7 This is a schematic diagram of the safety protection module for a high-reliability, high-precision pressure sensor.

[0024] Figure 8 For high reliability and high precision pressure sensors Figure 7 Enlarged structural diagram at point A in the middle.

[0025] The attached figures are labeled as follows: 1. Main body; 2. Countersunk mounting groove of the main body; 3. Mounting screws; 4. Positioning groove; 5. Force measuring core module; 501. Upper load-bearing top plate; 502. Countersunk mounting groove of the top plate; 503. Fastening screw one; 504. Force transmission upper plate; 505. Fastening screw two; 506. Pressure head; 507. Force concentration pressure point; 508. Force-to-electricity conversion core; 509. Countersunk mounting groove of the core; 510. Hex socket head cap screw; 6. Leveling auxiliary module; 60 1. Module connection panel; 602. Panel connection threaded hole; 603. Lower bearing base plate; 604. Scissor lift arm; 605. Hydraulic drive telescopic rod; 606. Lifting hydraulic cylinder; 7. Power supply box; 8. Safety protection module; 801. Protective strip; 802. Built-in hollow tube; 803. Lateral force touch sensor; 804. Impact buffer strip; 9. External mounting slot; 10. Audible and visual alarm buzzer; 11. Status indicator light strip. Detailed Implementation

[0026] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0027] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0028] Reference Figures 1-8A high-reliability, high-precision pressure sensor and its manufacturing process are disclosed, comprising: a main body 1, with countersunk mounting grooves 2 at the four corners of the main body 1, and mounting screws 3 extending through the countersunk mounting grooves 2 of the main body 1 and extending to the outside of the main body 1; a positioning groove 4 with an opening at the upper end of the main body 1; a force measuring core module 5 located in the positioning groove 4 inside the main body 1; leveling auxiliary modules 6 located on both sides of the force measuring core module 5 inside the main body 1; a power supply box 7 located on one side inside the main body 1; a safety protection module 8 located on the outside of the main body 1; external mounting grooves 9 on the four sides of the outside of the main body 1, and an audible and visual alarm buzzer 10 located in the external mounting groove 9; and status indicator light strips 11 located at the four corners of the main body 1. The power supply box 7 is electrically connected to the force measuring core module 5, the lateral force touch sensor 803, the audible and visual alarm buzzer 10, and the status indicator light strips 11, providing power to the entire component.

[0029] The force measuring core module 5 includes an upper bearing top plate 501, a countersunk mounting groove 502, a first fastening screw 503, a force transmission upper plate 504, a second fastening screw 505, a pressure head 506, a force concentration pressure point 507, a force-to-electricity conversion core 508, a countersunk mounting groove 509, and an internal hex bolt 510. The cross-section of the upper bearing top plate 501 is smaller than that of the positioning groove 4, and the top height of the upper bearing top plate 501 is higher than the highest point of the main body 1.

[0030] The upper support plate 501 has a countersunk mounting groove 502 on its surface. Fastening screw 503 passes through the countersunk mounting groove 502 to connect the upper support plate 501 with the force transmission plate 504. Fastening screw 505 is symmetrically provided on both sides of the force transmission plate 504.

[0031] The force measuring core module 5 adopts a layered coaxial force-bearing design. The cross-section of the upper bearing top plate 501 is smaller than that of the positioning groove 4 and the top height is higher than that of the highest point of the main body 1. This can achieve rapid positioning and assembly, prevent lateral movement, and ensure that the external pressure is fully applied to the force measuring part and avoid pressure loss. With the countersunk mounting groove 502 of the top plate and the countersunk connection structure of the fastening screw 503, a seamless fastening connection is achieved between the upper bearing top plate 501 and the force transmission upper plate 504. There is no external protrusion interference and the assembly fit is higher.

[0032] The pressure head 506 is fixed to the bottom end of the force transmission plate 504. The force concentration pressure point 507 is located at the center of the bottom end of the pressure head 506. The force-to-electric conversion core 508 is located directly below the force concentration pressure point 507. The surface of the force-to-electric conversion core 508 is provided with annular countersunk mounting grooves 509 at equal intervals. The internal hex bolts 510 are assembled inside the countersunk mounting grooves 509. The force concentration pressure point 507 adopts a conical solid boss structure. The center of the force concentration pressure point 507 is coaxially arranged with the pressure head 506 and the force center of the force conversion core 508.

[0033] The force transmission plate 504 is securely connected via symmetrical fastening screws 505 on both sides. The pressure head 506 fixed at the bottom, combined with the force concentration pressure point 507 with a conical solid boss structure, can efficiently concentrate and directionally transmit external pressure, effectively avoiding pressure dispersion and attenuation. At the same time, relying on the structure of the force concentration pressure point 507, pressure head 506, and force-to-electric conversion core 508 with their force centers arranged coaxially, the detection error caused by force eccentricity and lateral force is eliminated from the root. In addition, the countersunk mounting grooves 509 and hexagon socket bolts 510 on the surface of the force-to-electric conversion core 508 are equidistantly opened in annular shape, so that the force-to-electric conversion core 508 can be installed smoothly without loosening and the force plane remains horizontal throughout the entire process. This comprehensively improves the pressure transmission efficiency and transmission accuracy, thereby ensuring accurate force measurement and stable operation of the sensor, and greatly improving the overall detection accuracy and reliability.

[0034] The leveling auxiliary module 6 includes a module connection panel 601, a panel connection threaded hole 602, a lower bearing base plate 603, a scissor lift arm 604, a hydraulically driven telescopic rod 605, and a lifting hydraulic cylinder 606. The module connection panel 601 has a panel connection threaded hole 602 at the position corresponding to the second fastening screw 505. The module connection panel 601 is fixedly connected to the bottom end of the force transmission upper plate 504 through the panel connection threaded hole 602 and the second fastening screw 505.

[0035] The top of the scissor lift boom 604 is hinged to the module connection panel 601, and the bottom is hinged to the lower bearing base plate 603. The lifting hydraulic cylinder 606 drives and connects to the hydraulically driven telescopic rod 605. The end of the hydraulically driven telescopic rod 605 away from the lifting hydraulic cylinder 606 is connected to the module connection panel 601.

[0036] The scissor lift boom 604 adopts a symmetrical double scissor structure, with the hydraulically driven telescopic rod 605 and the lifting hydraulic cylinder 606 symmetrically arranged along the central axis of the scissor lift boom 604.

[0037] The leveling auxiliary module 6 adopts a hydraulically driven symmetrical lifting structure design. The module connection panel 601, through the panel connection threaded hole 602 and fastening screw 505, can accurately dock and firmly lock with the bottom end of the force transmission upper plate 504, ensuring smooth linkage with the force measuring core module during the leveling process without misalignment. The top of the scissor-type lifting arm 604 is hinged to the module connection panel 601, and the bottom is hinged to the lower bearing base plate 603. With the symmetrical double scissor structure, and the lifting hydraulic cylinder 606 and hydraulically driven telescopic rod 605 symmetrically arranged along the central axis of the scissor-type lifting arm 604, it can achieve uniform transmission of hydraulic driving force and balanced lifting force, eliminating the problems of skew and jamming during the lifting process. It can accurately drive the module connection panel 601 to lift and lower smoothly, thereby quickly correcting the levelness of the top force measuring core module, eliminating the force measurement deviation caused by uneven installation surface and running offset. The leveling action is stable and the accuracy is controllable throughout the process. It can adapt to a variety of complex installation scenarios and continuously ensure the coaxiality of the sensor force measurement.

[0038] The safety protection module 8 includes a protective strip 801, an internal hollow tube 802, a lateral force contact sensor 803, and an impact buffer strip 804. The protective strip 801 covers the outer edge of the main body 1, the internal hollow tube 802 is embedded inside the protective strip 801, and the internal hollow tube 802 is equipped with a lateral force contact sensor 803.

[0039] Multiple lateral force touch sensors 803 are provided, and the multiple lateral force touch sensors 803 are evenly distributed inside the built-in hollow tube 802. Two impact buffer strips 804 are provided between the built-in hollow tube 802 and the protective strip 801, and the two impact buffer strips 804 are in a V-shaped structure.

[0040] The safety protection module 8 adopts a fully enclosed buffer and early warning integrated structure. The protective strip 801 is wrapped around the outer edge of the main body 1, which can fully wrap the sensor body 1 and resist external bumps and lateral impacts. Multiple lateral force contact sensors 803 are evenly arranged inside the built-in hollow tube 802 embedded in the protective strip 801, which can realize full-area monitoring without blind spots on the outer side of the main body 1 and accurately capture various abnormal lateral forces and overload impact signals. In conjunction with the two impact buffer strips 804 arranged in a V-shape between the built-in hollow tube 802 and the protective strip 801, it can buffer and disperse the external force in multiple stages, greatly reducing the damage of external forces to the internal core force measuring components. At the same time, relying on the force guidance of the V-shaped structure, it further improves the buffer and force dissipation effect, taking into account both physical protection and real-time abnormal early warning functions, which can effectively extend the overall service life of the sensor.

[0041] A fabrication process for a high-reliability, high-precision pressure sensor includes the following steps: S1: Substrate pretreatment and main body 1 forming: High-strength corrosion-resistant alloy substrate is selected. The main body 1 is formed by precision forging and CNC precision machining. The countersunk mounting groove 2, positioning groove 4, and outer mounting groove 9 of the main body are precision machined simultaneously. The inner wall of the main body 1 and the contact surface of the positioning groove 4 are mirror polished to control the surface roughness ≤0.8μm and remove processing burrs and internal stress. S2: Precision machining and calibration of the core force measuring components. The pressure head 506 and the force concentration pressure point 507 with a conical solid structure are machined using an integrated precision turning process to ensure that the coaxiality error of the pressure head 506, the force concentration pressure point 507 and the force-electric conversion core 508 is ≤0.02mm. The force-electric conversion core 508 is subjected to patch mounting, temperature drift calibration and zero point calibration, and the core countersunk mounting groove 509 is machined to ensure that the flatness of the force-electric conversion core 508 meets the standard. S3: Leveling auxiliary module 6 assembly and debugging, sequentially process module connection panel 601, lower bearing base plate 603, scissor lifting arm 604, precisely hinge hydraulic drive telescopic rod 605, lifting hydraulic cylinder 606 with scissor lifting arm 604, assemble into double scissor leveling structure, pre-adjust the stroke and lifting accuracy of lifting hydraulic cylinder 606 to ensure that module connection panel 601 is horizontally raised and lowered without deviation; S4: Precise assembly of core components. Fix the qualified leveling auxiliary module 6 to the corresponding position inside the main body 1. Lock the force transmission upper plate 504 to the module connection panel 601 through fastening screw 2 505 and panel connection threaded hole 602. Then, firmly connect the upper bearing top plate 501 to the force transmission upper plate 504 through fastening screw 1 503. The force-electric conversion core 508 is fixed to the position of the force concentration pressure point 507 inside the main body 1 through internal hex bolt 510. The assembly torque is controlled to be consistent throughout the process. S5: Electrical module integration wiring, fix the power supply box 7 in the preset position inside the main body 1, complete the wiring and sealing of the power supply box 7 with the force measurement core module 5, the lateral force touch sensor 803, the sound and light alarm buzzer 10, and the status indicator light strip 11, and perform insulation and anti-interference treatment. S6: The safety protection module 8 is packaged by integrally injection molding the built-in hollow tube 802 of the built-in lateral force touch sensor 803 and the V-shaped impact buffer strip 804 into a protective strip 801. The protective strip 801 is tightly wrapped around the outer edge of the main body 1 to achieve full edge enclosure protection. S7: Overall calibration and finished product inspection, power-on debugging and leveling auxiliary module 6, leveling of force measurement core module 5, pressure accuracy retest, lateral force touch sensitivity test, and audible and visual alarm and status indication function verification. After passing the verification, the final fixing of mounting screws 3, audible and visual alarm buzzer 10, and status indication light strip 11 is completed to obtain the finished sensor.

[0042] During use, the external pressure at the upper end of the main body 1 directly acts on the upper bearing plate 501 of the force measuring core module 5. The upper bearing plate 501 evenly transmits the pressure to the force transmission plate 504, and then through the force concentration point 507 at the bottom of the pressure head 506, the pressure is coaxially and centrally transmitted to the force-to-electric conversion core 508. The force-to-electric conversion core 508 converts the mechanical pressure signal into a corresponding electrical signal, completing the pressure detection and signal output. The entire force path is single and without eccentricity, ensuring detection accuracy. During sensor installation or operation, horizontal correction can be achieved through the leveling auxiliary module 6: the lifting hydraulic cylinder 606 drives the hydraulic drive telescopic rod 605 to extend and retract, driving the symmetrical scissor-type lifting arm 604 to rise and fall smoothly, thereby adjusting the level of the module connection panel 601 and the top force measuring core module 5, ensuring that the force concentration point 507 and the force-to-electric conversion core 508 always remain aligned and coaxial, eliminating detection errors caused by tilting. The safety protection module 8 operates in real time throughout the process: the outer protective strip 801 of the main body 1, together with the V-shaped impact buffer strip 804, buffers and dissipates external lateral impact forces, protecting internal components; multiple sets of lateral force touch sensors 803 inside the built-in hollow tube 802 monitor external impact and overload force signals in real time. Once abnormal force is detected, the signal is immediately transmitted to the control system, triggering the audible and visual alarm buzzer 10 to issue an audible and visual warning. At the same time, the status indicator light strip 11 switches the light status synchronously, which facilitates the staff to quickly check for abnormalities and avoid sensor overload damage; the power supply box 7 provides stable power to the force measurement core module 5, the leveling auxiliary module 6, the lateral force touch sensor 803, the audible and visual alarm buzzer 10, and the status indicator light strip 11 throughout the process, ensuring the continuous and stable operation of each module; the entire set of sensors is fixedly installed through the countersunk mounting groove 2 of the main body and the mounting screws 3, which is convenient for disassembly and assembly and is suitable for long-term continuous measurement and control conditions.

[0043] Therefore, although the invention has been described herein with reference to specific embodiments thereof, freedom of modification, various changes and substitutions are also within the scope of the foregoing disclosure, and it should be understood that in some cases, certain features of the invention may be adopted without departing from the scope and spirit of the invention and without corresponding use of other features. Thus, many modifications can be made to adapt a particular environment or material to the essential scope and spirit of the invention. The invention is not intended to be limited to the specific terminology used in the following claims and / or the specific embodiments disclosed as the best mode for carrying out the invention, but the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Therefore, the scope of the invention will be defined only by the appended claims.

Claims

1. A high-reliability, high-precision pressure sensor, characterized in that, include: The main body (1) has countersunk mounting grooves (2) at the four corners of its surface, and mounting screws (3) are provided through the countersunk mounting grooves (2) of the main body (1), extending to the outside of the main body (1). The upper end of the main body (1) has an open positioning groove (4). A force measuring core module (5) is provided in the positioning groove (4) inside the main body (1). A leveling auxiliary module (6) is provided on both sides of the force measuring core module (5) inside the main body (1). The main body (1) has a power supply box (7) on one side and a safety protection module (8) on the outside. The main body (1) has an outer mounting slot (9) on all four sides and an audible and visual alarm buzzer (10) in the outer mounting slot (9). The main body (1) has a status indicator light strip (11) at each of its four corners. The power supply box (7) is electrically connected to the force measurement core module (5), the lateral force touch sensor (803), the audible and visual alarm buzzer (10), and the status indicator light strip (11) to supply power to the entire component.

2. The high-reliability, high-precision pressure sensor according to claim 1, characterized in that, The force measuring core module (5) includes an upper bearing top plate (501), a countersunk mounting groove (502), a fastening screw one (503), a force transmission upper plate (504), a fastening screw two (505), a pressure head (506), a force concentration pressure point (507), a force-electric conversion core (508), a core countersunk mounting groove (509), and an internal hex bolt (510). The cross-section of the upper bearing top plate (501) is smaller than that of the positioning groove (4), and the top height of the upper bearing top plate (501) is higher than the highest point of the main body (1).

3. A high-reliability, high-precision pressure sensor according to claim 2, characterized in that, The upper bearing top plate (501) has a countersunk mounting groove (502) on its surface. The first fastening screw (503) passes through the countersunk mounting groove (502) to connect the upper bearing top plate (501) with the force transmission upper plate (504). The second fastening screw (505) is symmetrically provided on both sides of the force transmission upper plate (504).

4. A high-reliability, high-precision pressure sensor according to claim 3, characterized in that, The pressure head (506) is fixed to the bottom end of the force transmission plate (504). The force concentration pressure point (507) is located at the center of the bottom end of the pressure head (506). The force-to-electric conversion core (508) is located directly below the force concentration pressure point (507). The surface of the force-to-electric conversion core (508) is provided with a countersunk mounting groove (509) in an annular shape. The internal hex bolt (510) is assembled inside the countersunk mounting groove (509). The force concentration pressure point (507) adopts a conical solid boss structure. The center of the force concentration pressure point (507) is coaxially arranged with the pressure head (506) and the force-to-electric conversion core (508) at three points.

5. A high-reliability, high-precision pressure sensor according to claim 1, characterized in that, The leveling auxiliary module (6) includes a module connection panel (601), a panel connection threaded hole (602), a lower bearing base plate (603), a scissor lift arm (604), a hydraulically driven telescopic rod (605), and a lifting hydraulic cylinder (606). The module connection panel (601) has a panel connection threaded hole (602) at the position corresponding to the fastening screw two (505). The module connection panel (601) is fixedly connected to the bottom end of the force transmission upper plate (504) through the panel connection threaded hole (602) and the fastening screw two (505).

6. A high-reliability, high-precision pressure sensor according to claim 5, characterized in that, The top of the scissor lift arm (604) is hinged to the module connection panel (601), and the bottom is hinged to the lower bearing base plate (603). The lifting hydraulic cylinder (606) is driven and connected to the hydraulic drive telescopic rod (605). The end of the hydraulic drive telescopic rod (605) away from the lifting hydraulic cylinder (606) is connected to the module connection panel (601).

7. A high-reliability, high-precision pressure sensor according to claim 6, characterized in that, The scissor lift arm (604) adopts a symmetrical double scissor structure, and the hydraulically driven telescopic rod (605) and the lifting hydraulic cylinder (606) are symmetrically arranged along the central axis of the scissor lift arm (604).

8. A high-reliability, high-precision pressure sensor according to claim 1, characterized in that, The safety protection module (8) includes a protective strip (801), an internal hollow tube (802), a lateral force touch sensor (803), and an impact buffer strip (804). The protective strip (801) is wrapped around the outer edge of the main body (1). The internal hollow tube (802) is embedded inside the protective strip (801), and the internal hollow tube (802) is provided with a lateral force touch sensor (803).

9. A high-reliability, high-precision pressure sensor according to claim 8, characterized in that, Multiple lateral force touch sensors (803) are provided, and the multiple lateral force touch sensors (803) are evenly distributed inside the built-in hollow tube (802). Two impact buffer strips (804) are provided between the built-in hollow tube (802) and the protective strip (801), and the two impact buffer strips (804) are in a V-shaped structure.

10. A fabrication process for a high-reliability, high-precision pressure sensor, employing the high-reliability, high-precision pressure sensor described in any one of claims 1-9, characterized in that, Includes the following steps: S1: Substrate pretreatment and main body (1) forming: High-strength corrosion-resistant alloy substrate is selected, and the main body (1) is formed by precision forging and CNC precision machining. The main body countersunk mounting groove (2), positioning groove (4) and outer mounting groove (9) are precision machined simultaneously. The inner wall of the main body (1) and the contact surface of the positioning groove (4) are mirror polished to control the surface roughness ≤0.8μm and remove processing burrs and internal stress. S2: Precision machining and calibration of core force measuring components. The pressure head (506) and the force concentration pressure point (507) of the conical solid structure are machined using an integrated precision turning process to ensure that the coaxiality error of the force center of the pressure head (506), the force concentration pressure point (507) and the force-electric conversion core (508) is ≤0.02mm. The force-electric conversion core (508) is patched, temperature drift calibrated and zero point calibrated, and the countersunk mounting groove (509) of the core is machined to ensure that the flatness of the installation of the force-electric conversion core (508) meets the standard. S3: The leveling auxiliary module (6) is assembled and debugged. The module connection panel (601), the lower bearing base plate (603), and the scissor lifting arm (604) are processed in sequence. The hydraulic drive telescopic rod (605), the lifting hydraulic cylinder (606) and the scissor lifting arm (604) are precisely hinged to form a double scissor leveling structure. The stroke and lifting accuracy of the lifting hydraulic cylinder (606) are pre-tested to ensure that the module connection panel (601) is horizontally lifted without deviation. S4: The core components are precisely assembled. The leveling auxiliary module (6) that has been debugged and qualified is fixed in the corresponding position inside the main body (1). The force transmission plate (504) and the module connection panel (601) are locked together by fastening screw two (505) and panel connection thread hole (602). The upper bearing plate (501) is then firmly connected to the force transmission plate (504) by fastening screw one (503). The force-electric conversion core (508) is fixed in the main body (1) with internal hex bolt (510) at the position directly opposite the force concentration pressure point (507). The assembly torque is controlled to be consistent throughout the process. S5: Electrical module integration wiring, fix the power supply box (7) in the preset position inside the main body (1), complete the wiring welding and sealing of the power supply box (7) and the force measurement core module (5), the lateral force touch sensor (803), the sound and light alarm buzzer (10), and the status indicator light strip (11), and do insulation and anti-interference treatment; S6: The safety protection module (8) is packaged by injection molding the built-in hollow tube (802) of the built-in lateral force touch sensor (803) and the V-shaped impact buffer strip (804) into a protective strip (801). The protective strip (801) is tightly wrapped around the outer edge of the main body (1) to achieve full edge protection. S7: Overall calibration and finished product inspection, power-on debugging and leveling auxiliary module (6), correct the level of the force measurement core module (5), perform pressure accuracy retest, lateral force touch sensitivity test, sound and light alarm and status indication function verification, and after passing the test, complete the final fixing of the mounting screw (3), sound and light alarm buzzer (10), and status indication light strip (11) to obtain the finished sensor.

Images