Salt tank with automatic alarm function

Abstract

The application discloses a salt tank with an automatic alarm function, and belongs to the technical field of water treatment equipment. The salt tank comprises a shell, an upper cover, an alarm device and an inductive device. The shell is formed with an internal space for containing solid salt and brine. The upper cover is covered on a top opening of the shell. The alarm device is installed on the upper cover or an outer wall of the shell. The inductive device is arranged on an inner bottom side of the shell. The inductive device is used for inducting gravity change of the solid salt overlaid thereon, and outputs a trigger signal when the gravity is lower than a preset threshold. The application realizes the automatic alarm function of the salt tank when the salt is insufficient. The application breaks through the limitation of the traditional salt tank as a passive container. The gravity of the solid salt is used as a direct sensing source. The mechanical inductive structure is used for accurately judging the residual salt amount in the tank. When the salt is about to be exhausted, the sound and light alarm is automatically triggered. The use convenience of the user and the operation reliability of the soft water system are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of water treatment equipment technology, and in particular to a salt tank with an automatic alarm function. Background Technology

[0002] In a water softening system, the brine tank is a key container for storing industrial salt (usually in bulk or granular form) and preparing saturated brine to regenerate ion exchange resins. The brine tank contains solid salt and is filled with a suitable amount of fresh water. Through the natural dissolution of the water, a high-concentration brine is formed. This brine is then piped out and transported to the main tank of the water softener to restore the resin's softening capacity.

[0003] However, existing conventional salt tanks have a very limited function; they are essentially just salt storage containers and lack the ability to sense the amount of salt remaining inside. In actual use, solid salt gradually decreases over time until it is completely depleted, but users cannot visually determine the real-time salt level from the outside. The current common practice is to rely on manual experience, periodically opening the tank lid for visual inspection, or roughly judging the level by tapping the tank or observing the brine concentration. This manual inspection method has many drawbacks: First, the timeliness is poor. The dissolution rate of salt is affected by factors such as water temperature and water consumption, making it difficult to predict accurately. If users do not check in time, once the salt is completely depleted, the water softener will directly output unsoftened hard water, causing scale buildup in downstream water-using equipment (such as boilers, water heaters, dishwashers, etc.), increased energy consumption, and even permanent damage to the equipment.

[0004] Secondly, it is labor-intensive and inefficient. For water softeners installed in basements or remote locations, frequent manual inspections are extremely inconvenient, consuming manpower and time, and are seriously out of step with the management needs of modern smart homes.

[0005] Third, there is a lack of effective early warning mechanisms. None of the existing salt tank products on the market integrate automatic alarm functions. Although some solutions exist that monitor the liquid level using float-type water level switches, there is no direct correlation between water level and salt quantity—even if the salt is depleted, the water level can still reach the normal height after replenishment. Therefore, water level monitoring cannot reflect the true state of salt shortage.

[0006] Given the shortcomings of the existing technologies, there is an urgent need in the field for a salt tank solution that is simple in structure, reliable in operation, and capable of real-time sensing of salt levels and automatically issuing an alarm when salt is low. However, no related technologies have been disclosed or similar technical concepts have been proposed to date. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a salt tank with an automatic alarm function, in order to solve the problem that the existing salt tanks cannot automatically sense the salt level and rely on manual inspection.

[0008] To achieve the above-mentioned objective, the first aspect of the present invention provides a salt tank with an automatic alarm function, comprising: The outer shell has an internal space for containing solid salt and brine. A top cover that closes onto the top opening of the outer casing; An alarm device is installed on the outer wall of the upper cover or the outer shell, and the alarm device includes at least one sound and light alarm. A sensing device is disposed on the inner bottom side of the housing. The sensing device is used to sense the gravity change of the solid salt pressed on it, and outputs a trigger signal when the gravity is lower than a preset threshold. The alarm device is electrically connected to the sensing device and performs an alarm action in response to the trigger signal.

[0009] Optionally, the sensing device includes: A base, which is fixedly installed on the bottom of the inner wall of the outer casing; The sensor body is disposed above the base, and a longitudinal through-hole is formed in the central area of ​​the sensor body; A movable top rod is axially slidably inserted into the hollow hole. The top end of the movable top rod protrudes from the upper surface of the sensor body under normal conditions to directly bear the pressure of the solid salt. A sensor switch is disposed above the base. When the movable push rod is pressed down to the first position by the salt block, the sensor switch is in the first state. When the movable push rod rises to the second position due to the decrease in the amount of salt above and is acted upon by the elastic reset member, the sensor switch switches to the second state and outputs the trigger signal.

[0010] Optionally, the sensing device further includes a waterproof seal made of flexible rubber. The waterproof seal covers the top opening of the perforated hole and is fitted onto the outer wall of the movable top rod to prevent salt water and salt particles from seeping into the sensor body.

[0011] Optionally, the sensing switch is a micro switch, and the contact of the micro switch is linked and engaged with the bottom end of the movable push rod; or, the sensing switch is a Hall switch, and a magnetic element cooperating with the Hall switch is fixedly provided on the movable push rod.

[0012] Optionally, the alarm device includes an alarm unit, an alarm light, and / or a buzzer.

[0013] Optionally, the alarm device includes a control circuit board, which integrates a controller and a power management module.

[0014] Optionally, the sensing device is electrically connected to the signal input terminal of the control circuit board via a wire, and the alarm light and / or buzzer is electrically connected to the signal output terminal of the control circuit board.

[0015] Optionally, the controller is configured to: upon receiving the trigger signal, control the alarm light to flash and simultaneously drive the buzzer to emit an intermittent sound.

[0016] Optionally, the power cord and signal cord of the sensing device extend to the outside through a through hole opened in the side wall of the housing, and a waterproof connector or sealing ring is provided at the through hole.

[0017] Optionally, a brine outlet is provided on the lower part of the side wall or the bottom of the housing. The brine outlet is connected to the regeneration tank of the water softener through a pipeline for extracting the saturated brine generated in the brine tank.

[0018] The beneficial effects of this invention are: 1. The salt tank with automatic alarm function of this invention realizes the function of automatic alarm when the salt tank is low. This invention breaks through the limitation of traditional salt tanks that are only passive containers. It uses the gravity of the solid salt itself as a direct sensing source. Through a mechanical sensing structure, it accurately judges the remaining salt in the tank and automatically triggers an audible and visual alarm when the salt is about to run out. This completely replaces the outdated method of manually opening the lid for periodic inspection, greatly improving the user's convenience and the operational reliability of the soft water system.

[0019] 2. The salt tank with automatic alarm function of the present invention has a simple structure, low cost, and is easy to promote. The sensing device used in the present invention is based on the gravity-mechanical triggering principle and is mainly composed of standard components such as a movable top rod, an elastic reset component, and a micro switch. It does not require complex electronic concentration sensors or expensive detection circuits. The overall structure is robust and durable, with low manufacturing cost, suitable for large-scale industrial production, and can be perfectly adapted to various existing salt tank products, with broad application prospects.

[0020] 3. The salt tank with automatic alarm function of this invention has high reliability and strong anti-interference ability. Because it directly detects the weight of solid salt, rather than relying on brine concentration or liquid level, the judgment logic of this invention is clear and direct, unaffected by factors such as water temperature changes, fluctuations in replenishment water level, or differences in salt quality. At the same time, by setting waterproof seals to effectively protect the sensor body, it ensures that the sensing device can maintain a stable and sensitive working state even in harsh environments with long-term high humidity and high salt spray.

[0021] 4. The salt tank with automatic alarm function of this invention has significant energy-saving, emission-reduction, and equipment protection benefits. Timely and accurate salt shortage alarms ensure that the water softener always operates with a sufficient salt source, avoiding problems such as resin failure and excessive water hardness caused by salt-free regeneration. This effectively protects downstream water-using equipment, extends equipment lifespan, and reduces energy waste and maintenance costs. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of the salt tank with automatic alarm function of the present invention; Figure 2 This is a cross-sectional schematic diagram of the salt tank with automatic alarm function of the present invention; Figure 3 This is a schematic diagram of the internal structure of the salt tank with automatic alarm function according to the present invention; Figure 4 This is a system structure block diagram of the salt tank with automatic alarm function according to the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Outer casing; 2. Top cover; 5. Alarm device; 7. Alarm light; 51. Control circuit board; 401. Base; 402. Sensor body; 404. Movable top rod; 408. Sensor switch.

[0024] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] Reference Figures 1 to 4 The salt tank in this embodiment mainly includes: outer shell 1, upper cover 2, alarm device and sensing device.

[0028] The outer casing 1 is a cubic or cylindrical box structure with an open top, containing a chamber for storing lumpy or granular industrial salt and the fresh water injected with dissolved salt. The outer casing 1 can be integrally molded from corrosion-resistant plastics such as polyethylene (PE) or polypropylene (PP) using rotational molding or injection molding processes to resist long-term corrosion from the brine. A brine outlet pipe is located at the bottom of the side wall of the outer casing 1. The inner end of this outlet pipe extends below the liquid surface inside the outer casing 1, and the outer end connects to the brine suction pipe of the water softener via a thread or quick connector for metered extraction of saturated brine.

[0029] The top cover 2 closes onto the top opening of the outer casing 1. The top cover 2 and the outer casing 1 can be detachably fixed by means of snaps, fasteners, or threads. A sealing ring is provided between the contact surfaces of the two to prevent external debris from falling into the box and to reduce the escape of moisture. A through hole is opened at the center of the top of the top cover 2 for installing the alarm device 5.

[0030] The alarm device includes an alarm unit 5 and an alarm light 7. The alarm unit 5 is a rectangular or circular plastic housing, which houses a control circuit board 51 (not shown in the figure). The control circuit board 51 integrates a controller (e.g., a microcontroller of model STC15W204S) and a power switch element for driving the alarm light 7. The alarm light 7 is preferably a high-brightness LED, which is fixedly mounted on the outer top surface of the alarm unit 5 and covered with a transparent or semi-transparent protective cover to transmit the light alarm signal outwards. The housing of the alarm unit 5 may also be equipped with a button for manual testing or reset (not shown in the figure).

[0031] In addition, an inlet pipe 3 is provided on one side of the outer casing 1. This inlet pipe 3 is used to connect to an external water source (such as a tap water pipe) to replenish fresh water into the brine tank in a measured amount. The outlet end of the inlet pipe 3 extends into the interior of the outer casing 1 and can be equipped with a float valve (not shown) to automatically control the highest water level in the tank.

[0032] The sensing device is fixedly installed in the center area of ​​the bottom of the inner wall of the outer casing 1. As the core innovative component of this invention, its specific structure is as follows: The sensing device includes a fixed base 401, which is a disc-shaped or square plate-shaped structure, and is fixedly connected to the inner bottom surface of the housing 1 by bolts or clamps. A cylindrical sensor body 402 is vertically arranged above the fixed base 401, and the sensor body 402 is integrally formed with the fixed base 401 or fixed by adhesive.

[0033] A longitudinal through-hole is provided at the central axis of the sensor body 402. A movable push rod 404 is inserted through the through-hole. The movable push rod 404 is a cylindrical rod whose axis coincides with the axis of the through-hole, and the outer diameter of the movable push rod 404 is slightly smaller than the inner diameter of the through-hole, forming a sliding fit clearance between the two, so that the movable push rod 404 can slide freely along the axis within the through-hole.

[0034] The top of the movable top rod 404 protrudes a certain height (e.g., 5-15mm) from the upper surface of the sensor body 402 in the initial state, and this protruding part directly bears the pressure of the solid salt above.

[0035] An elastic reset element is fitted onto the lower section of the movable push rod 404, which is preferably a compression spring in this embodiment. The upper end of the compression spring abuts against the lower end face of the sensor body 402. The compression spring is always in a compressed and energy-storing state, applying a vertically upward elastic thrust to the movable push rod 404, so that the movable push rod 404 can spring upward when there is no external pressure.

[0036] To prevent salt water from seeping into the sensor body 402 through the gap between the movable push rod 404 and the perforated hole, this embodiment provides a waterproof seal at the top opening of the perforated hole. This waterproof seal is made of a salt-resistant flexible rubber material (such as fluororubber or silicone rubber), and its overall structure is annular or cap-shaped. It is tightly fitted onto the outer wall of the movable push rod 404, and the outer periphery of the waterproof seal is fixedly attached to the upper end face of the sensor body 402. This waterproof seal ensures the free axial sliding of the movable push rod 404 while effectively preventing salt water and salt particles from entering the sensor, thus providing excellent dynamic sealing.

[0037] The sensing device also includes a sensing switch 408. In this embodiment, the sensing switch 408 is a micro switch with a simple structure and large contact capacity. The micro switch is fixedly installed on the upper surface of the fixed base 401, and its contact is directly opposite the bottom end of the movable push rod 404. When the movable push rod 404 is pressed down by the salt block above, it moves down synchronously and presses the contact of the micro switch, causing the normally open contact of the micro switch to close; when the movable push rod 404 rises under the action of the compression spring due to the decrease of the amount of salt above, it releases the pressure on the contact, the micro switch resets, its normally open contact opens, and a level transition signal is generated as a trigger signal.

[0038] In another variant embodiment not shown, the sensor switch 408 can also be a Hall switch. In this case, a magnetic element (such as a neodymium magnet) is fixedly embedded in the side wall or bottom of the movable push rod 404. When the movable push rod 404 moves up and down, the relative position of the magnetic element and the Hall switch changes, and the Hall switch outputs a corresponding voltage signal, which can also realize the position detection function.

[0039] The sensing device is electrically connected to the control circuit board 51 inside the alarm device 5 via a wire. The wire passes through a lead hole on the side wall of the sensor body 402 and is led out to the outside through a waterproof connector on the side wall of the housing 1. In this embodiment, the DC operating power (e.g., DC 5V or DC 12V) required by the sensing device is provided by an external power adapter, which also supplies power to the alarm device 5. The signal line in the wire is used to transmit the on / off status signal of the microswitch to the controller in real time.

[0040] The working principle and alarm logic of the present invention will be explained in detail below with reference to the complete working process of the salt tank in this embodiment.

[0041] First, the user adds fresh water to the inside of the salt tank shell 1 through the inlet pipe 3, while simultaneously adding large chunks or granules of industrial salt (not shown in the figure) through the top opening. The solid salt accumulates at the bottom of the shell 1 under its own weight, directly pressing against the top of the movable push rod 404 of the sensing device. At this point, the weight of the solid salt overcomes the elastic force of the compression spring, pushing the movable push rod 404 downwards to the first position. In this first position, the bottom end of the movable push rod 404 presses down on the contact of the microswitch, causing the internal circuit of the microswitch to be in a conductive state (i.e., closed in the case of a normally open type). In this state, the controller's signal input receives a low-level or ground signal, and the controller determines that the current salt level is sufficient and does not trigger an alarm.

[0042] As the water softener continues to operate, the fresh water inside the outer casing 1 continuously dissolves solid salts. The resulting saturated brine is gradually drawn out through the outlet pipe to the main tank of the water softener for resin regeneration. The dissolution process begins on the surface of the solid salts and gradually progresses inward and downward. When the solid salts are almost completely dissolved, the weight of the salt block accumulated at the bottom of the outer casing 1 and pressing against the movable push rod 404 is significantly reduced. When this weight is less than the preload threshold of the compression spring, the compression spring pushes the movable push rod 404 upward to the second position. In this second position, the microswitch contacts switch from a closed state to an open state, and the level at the controller signal input changes from low to high (or from high to low, depending on the circuit design). This level change is the trigger signal.

[0043] After detecting the trigger signal, the controller performs debouncing processing (e.g., reconfirming the level status after a 50ms delay) to eliminate false triggers that may be caused by vibration. Once the salt deficiency status is confirmed, the controller immediately activates the alarm light 7, causing it to flash rapidly at a frequency of 1Hz. In a preferred embodiment, the alarm device 5 also integrates a buzzer, which the controller simultaneously drives to emit intermittent "beep-beep" alarm sounds. This dual audible and visual alarm ensures that users are promptly informed of the salt deficiency information regardless of whether it is a noisy daytime environment or a quiet nighttime environment.

[0044] When the user hears or sees the alarm signal, simply open the top cover 2 and add sufficient new industrial salt to the inside of the outer casing 1. The newly added solid salt presses down on the upper end of the movable top rod 404, causing the movable top rod 404 to move back to the first position. The micro switch resumes conduction, the controller automatically resets after detecting the signal change, the alarm light 7 goes out, the buzzer stops sounding, and the salt tank returns to normal operation.

[0045] Considering that the salt tank is in a harsh environment with high humidity and high salt spray for a long time, this invention has made many targeted designs in terms of waterproofing and protection.

[0046] First, as mentioned earlier, a flexible rubber waterproof seal is provided at the top of the hollow hole of the sensor body 402. This seal effectively prevents salt water from seeping into the sensor through the sliding gap of the movable top rod 404, ensuring that the inside of the sensor body 402 is always kept dry and avoiding corrosion of metal parts (such as compression springs, micro switch pins, etc.) by salt spray.

[0047] Secondly, a rubber gasket is provided between the fixed base 401 of the sensing device and the bottom of the inner wall of the outer casing 1 to prevent salt water from seeping into the bottom through the installation gap.

[0048] Furthermore, a professional waterproof cable connector (such as a PG type waterproof connector) is installed at the through hole on the side wall of the outer casing 1 for threading the wire. This connector uses an internal conical sealing ring to hold the outer sheath of the wire and is tightened and sealed by a locking nut, achieving a protection level of IP67 or higher, which can completely eliminate the risk of salt water leaking out along the wire.

[0049] The control circuit board 51 inside the alarm device 5 is equipped with a main control chip U1 (model STM8S003F3) and a step-down voltage regulator module U2 (such as LM2596) that provides regulated power to the chip and peripheral circuits. The externally input DC12V power supply is converted to DC5V by the step-down voltage regulator module U2 to provide the operating voltage for the main control chip U1 and the micro switch S1.

[0050] One end (common terminal) of the microswitch S1 in the sensing device is connected to ground GND, and the other end (normally open terminal) is connected as a signal output terminal to the GPIO input pin (e.g., PA1) of the main control chip U1. This GPIO pin is internally connected to VCC (5V) via a pull-up resistor (e.g., 10kΩ). When the microswitch S1 is not pressed (i.e., in the salt-deficient state), its normally open terminal is open, and the GPIO pin is pulled high by the pull-up resistor; when the microswitch S1 is pressed (i.e., in the salt-sufficient state), its normally open terminal closes with the common terminal, and the GPIO pin is pulled low.

[0051] The alarm light 7 uses a high-brightness red LED. Its anode is connected to the PWM output pin (e.g., PB1) of the main control chip U1 through a current-limiting resistor R1 (e.g., 220Ω), and its cathode is connected to ground. The positive terminal of the buzzer (preferably an active buzzer) is connected to another GPIO output pin (e.g., PB2) of the main control chip U1, and its negative terminal is grounded.

[0052] When the main control chip U1 detects a high level on the GPIO pin and confirms it continuously, it determines that the salt is insufficient. At this time, the main control chip U1 controls the PB1 pin to output a 1Hz PWM pulse signal, driving the LED alarm light 7 to flash; at the same time, it controls the PB2 pin to output a high level, causing the buzzer to emit a continuous or intermittent sound. When salt is replenished, the GPIO pin goes low, and the main control chip U1 immediately stops all alarm outputs.

[0053] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A salt tank with an automatic alarm function, characterized in that, include: The outer shell (1) has an internal space for containing solid salt and brine; The top cover (2) is closed at the top opening of the outer shell (1); An alarm device (5) is installed on the outer wall of the top cover (2) or the outer shell (1), and the alarm device (5) includes at least one sound and light alarm. The sensing device is located on the inner bottom side of the outer shell (1). The sensing device is used to sense the gravity change of the solid salt pressed on it, and outputs a trigger signal when the gravity is lower than a preset threshold. The alarm device (5) is electrically connected to the sensing device and performs an alarm action in response to the trigger signal.

2. The salt tank with automatic alarm function according to claim 1, characterized in that, The sensing device includes: A base (401) is fixedly installed on the bottom of the inner wall of the outer casing (1); The sensor body (402) is disposed above the base (401), and a longitudinal through-hole is provided in the central area of ​​the sensor body (402); The movable top rod (404) is axially slidably inserted into the hollow hole. The top end of the movable top rod (404) protrudes from the upper surface of the sensor body (402) under normal conditions to directly bear the pressure of the solid salt. A sensor switch (408) is disposed above the base (401). When the movable top rod (404) is pressed down to the first position by the salt block, the sensor switch (408) is in the first state. When the movable top rod (404) rises to the second position under the action of the elastic reset member due to the reduction of the amount of salt above, the sensor switch (408) switches to the second state and outputs the trigger signal.

3. The salt tank with automatic alarm function according to claim 2, characterized in that, The sensing device also includes a waterproof seal made of flexible rubber. The waterproof seal covers the top opening of the hollow hole and is fitted onto the outer wall of the movable top rod (404) to prevent salt water and salt particles from seeping into the sensor body (402).

4. The salt tank with automatic alarm function according to claim 2, characterized in that, The sensor switch (408) is a micro switch, and the contact of the micro switch is linked with the bottom end of the movable push rod (404); or, the sensor switch (408) is a Hall switch, and a magnetic element that cooperates with the Hall switch is fixedly provided on the movable push rod (404).

5. The salt tank with automatic alarm function according to claim 1, characterized in that, The alarm device (5) includes an alarm device (5), an alarm light (7), and / or a buzzer.

6. The salt tank with automatic alarm function according to claim 5, characterized in that, The alarm device (5) is equipped with a control circuit board (51), which integrates a controller and a power management module.

7. The salt tank with automatic alarm function according to claim 5, characterized in that, The sensing device is electrically connected to the signal input terminal of the control circuit board (51) via a wire, and the alarm light (7) and / or buzzer is electrically connected to the signal output terminal of the control circuit board (51).

8. The salt tank with automatic alarm function according to claim 1, characterized in that, The controller is configured to: upon receiving the trigger signal, control the alarm light (7) to flash and simultaneously drive the buzzer to emit an intermittent sound.

9. The salt tank with automatic alarm function according to claim 2, characterized in that, The power line and signal line of the sensing device pass through the through hole opened on the side wall of the housing (1) to the outside, and a waterproof connector or sealing ring is provided at the through hole.

10. The salt tank with automatic alarm function according to claim 1, characterized in that, The lower part or bottom of the side wall of the outer shell (1) is provided with a brine outlet, which is connected to the regeneration tank of the water softener through a pipeline to extract the saturated brine generated in the salt tank.

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