A glass plate liquid level meter capable of remote control

Abstract

The application discloses a glass plate liquid level meter capable of remote control, which comprises a meter body and a glass plate, and further comprises a liquid level detection module for measuring the liquid level height, a microcontroller connected with the liquid level detection module, pre-processing of the liquid level data, and real-time transmission of the processed liquid level data to a remote control center through a wireless communication module, an electric regulating valve connected with the microcontroller, control of the electric regulating valve opening degree according to the remote control instruction and the preset upper and lower limits of the liquid level, a diaphragm pump connected with the microcontroller, a seal disc built-in in a liquid storage barrel and capable of lifting and sliding, the seal disc divides the space in the liquid storage barrel into two independent spaces, and the microcontroller is built-in with an adaptive liquid level adjusting algorithm. The application has the advantages that the operator can master the dynamic change of the liquid level in real time without going to the site, automatically and quickly respond to and adjust the liquid level height, and the accuracy and stability of the liquid level control are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of level gauge technology, specifically a glass plate level gauge capable of remote control. Background Technology

[0002] In numerous industrial production sectors such as petrochemicals, power generation, pharmaceuticals, and food processing, accurate monitoring and precise control of liquid levels within containers are crucial. Precise control of liquid levels directly impacts the stability and continuity of the production process, significantly affecting product quality, energy consumption, and production safety.

[0003] Traditional glass plate level gauges, based on the principle of communicating vessels, allow operators to directly observe the liquid level within the container using a transparent glass plate. However, these gauges have significant limitations. Firstly, they only allow for local observation. In modern large-scale industrial enterprises, production equipment is widely distributed, and workshops are large. Operators relying on such gauges would need to spend considerable time constantly patrolling and checking the liquid level, resulting in low efficiency and difficulty in monitoring real-time dynamic changes. This fails to meet the real-time and high-efficiency requirements of modern industrial automation. Secondly, traditional glass plate level gauges cannot automatically and quickly respond to and adjust the liquid level in the face of fluctuations. Manual operation of valves or pumps is required, which is slow and susceptible to human error, such as misjudgment or delayed operation. This makes it impossible to guarantee that the liquid level is always at its optimal operating state, increasing instability and safety risks in the production process. Summary of the Invention

[0004] The purpose of this invention is to provide a glass plate level gauge capable of remote control in order to solve the above-mentioned problems.

[0005] The present invention achieves the above objectives through the following technical solution: a glass plate level gauge capable of remote control, comprising a gauge body and a glass plate, and further comprising a level detection module, wherein the probes are evenly spaced along the height direction of the glass plate for measuring the level height;

[0006] The data processing and remote transmission module includes a microcontroller and a wireless communication module integrated on the microcontroller. The microcontroller is connected to the liquid level detection module, preprocesses the liquid level data, and transmits the processed liquid level data to the remote control center in real time through the wireless communication module.

[0007] The actuator and control module include an electric regulating valve installed on the pipeline connecting the liquid storage tank and the liquid storage tank, which are connected to the meter body. The data processing and remote transmission module is installed on the outer wall of the liquid storage tank. The electric regulating valve is connected to a microcontroller. The microcontroller controls the opening of the electric regulating valve according to the remote control command and the preset upper and lower limits of the liquid level, thereby adjusting the liquid level height.

[0008] It also includes a diaphragm pump connected to the end of the reservoir away from the surface, the diaphragm pump being connected to a microcontroller, and the reservoir having a built-in lifting and sliding sealing disc that divides the reservoir's interior into two independent spaces.

[0009] The microcontroller has a built-in adaptive liquid level regulation algorithm, which can automatically adjust the control parameters of the electric regulating valve according to the speed and magnitude of liquid level changes.

[0010] Preferably, valves are connected to both the upper and lower ends of the watch body, and safety steel balls are installed inside the valves. When the glass plate breaks, the safety steel balls block the channel connecting the watch body and the container under the pressure inside the container.

[0011] Preferably, the outer wall of the watch body is provided with a scale, which is arranged along the axial direction of the watch body and corresponds to the display area of ​​the glass plate;

[0012] The glass plate is disposed inside the watch body and communicates with the inner cavity of the watch body. Both sides of the glass plate are provided with pressure caps to clamp and fix the glass plate inside the watch body.

[0013] The gland has a threaded hole, and a bolt is inserted through the threaded hole on one side of the gland, and the end of the bolt passes through the other side of the gland and is threaded to a nut.

[0014] Preferably, the two valve openings at the upper and lower ends are connected to mating flanges, and the two ends of the meter body are also connected to external valves. One of the external valves is connected to one end of the liquid storage tank through a flange, thereby connecting the liquid storage tank to the inner cavity of the meter body.

[0015] Preferably, the liquid level detection module is a capacitive liquid level sensor probe. The output terminal of the capacitive liquid level sensor is connected to the general-purpose input / output pin of the microcontroller through a shielded cable. An analog-to-digital converter is provided between the microcontroller and the liquid level sensor, and the GPIO pin of the microcontroller is connected to the input terminal of the analog-to-digital converter.

[0016] Preferably, the microcontroller is an STM32 controller, and the microcontroller's SPI master output slave input (MOSI) pin is connected to the SPI data input pin of the wireless communication module, and the master input slave output (MISO) pin is connected to the SPI data output pin of the wireless communication module.

[0017] Preferably, the microcontroller signal input terminal is provided with a filtering circuit, which includes resistors and capacitors to form a low-pass filter circuit. The low-pass filter circuit reasonably selects the resistor and capacitor parameters according to the frequency characteristics of the liquid level signal, so that the cutoff frequency effectively filters out noise components higher than the liquid level signal frequency.

[0018] Preferably, the electric regulating valve is equipped with a motor driver and a position feedback device. The motor driver is connected to the GPIO pin of a microcontroller. The microcontroller controls the motor driver by outputting pulse width modulation (PWM) signals with different duty cycles, thereby driving the opening of the electric regulating valve.

[0019] The position feedback device of the electric regulating valve is a potentiometer. The output signal of the potentiometer is connected to the input pin of the microcontroller. The sliding end of the potentiometer is connected to the valve stem of the electric regulating valve. When the valve stem moves, the resistance value of the potentiometer changes, and the output voltage signal corresponds to the valve opening. The microcontroller collects the voltage signal and obtains the current opening information of the electric regulating valve in real time.

[0020] Preferably, the adaptive liquid level adjustment algorithm uses the liquid level change rate and amplitude as input parameters;

[0021] Liquid level change rate v= , where t n At the current moment, L n For the corresponding liquid level value, t n-1 For the previous moment, L n-1 This refers to the liquid level value.

[0022] The liquid level change range is the difference between the current liquid level value and the set target liquid level value L. target The difference, i.e., the amplitude A=L n- L target .

[0023] Preferably, the GPIO pin of the microcontroller is connected to the negative terminal of the relay coil of the diaphragm pump via a current-limiting resistor, and the positive terminal of the relay coil is connected to the positive terminal of the power supply. This pin will be used to output signals controlling the start and stop of the diaphragm pump;

[0024] One independent space is used for liquid storage, and the other independent space provides space for the lifting and sliding of the sealing disc and is connected to the hydraulic interface of the diaphragm pump;

[0025] When the liquid level exceeds the preset upper limit, the diaphragm pump draws liquid from the container into the storage tank;

[0026] When the liquid level is lower than the preset lower limit, the diaphragm pump pumps the solution in the storage tank into the container.

[0027] The beneficial effects of this invention are:

[0028] 1. This invention accurately measures the liquid level by setting a liquid level detection module and uses an integrated wireless communication module for data processing and remote transmission to transmit the liquid level data to a remote control center in real time. This solves the problem that traditional glass plate liquid level gauges can only be observed locally, meets the real-time requirements of modern industrial automation production, and allows operators to monitor the dynamic changes in the liquid level in real time without being physically present on site, greatly improving production efficiency.

[0029] 2. The electric regulating valve and diaphragm pump in the actuator and control module of this invention, under the synergistic effect of the microcontroller and the built-in adaptive liquid level adjustment algorithm, can automatically and quickly respond to and adjust the liquid level height according to remote control commands, preset upper and lower limits of liquid level, and the speed and amplitude of liquid level changes. Compared with the traditional manual operation of valves or pumps, it avoids the influence of human factors, significantly improves the accuracy and stability of liquid level control, reduces safety risks in the production process, and ensures the stability and continuity of the production process. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0032] Figure 2 This is a schematic diagram of the liquid level gauge structure of the present invention;

[0033] Figure 3 This is a schematic diagram of the liquid storage tank structure of the present invention;

[0034] Figure 4 This is a cross-sectional view of the liquid storage tank of the present invention.

[0035] In the diagram: 1. Gauge body; 2. Cover; 3. Valve; 4. Liquid level detection module; 5. Valve; 6. Storage tank; 61. Sealing plate; 7. Data processing and remote transmission module; 8. Electric regulating valve; 9. Diaphragm pump. Detailed Implementation

[0036] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0037] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0038] Please see Figure 1-4 As shown, this invention provides a glass plate level gauge capable of remote control, comprising a gauge body 1 and a glass plate. Valves 3 are connected to both the upper and lower ends of the gauge body 1, and each valve 3 contains a safety steel ball. When the glass plate is operating normally, the safety steel ball is in the open position under the action of spring force or gravity, and the gauge body 1 is in communication with the container. When the glass plate accidentally breaks, the liquid or gas pressure inside the container pushes the safety steel ball to the sealing position, where it tightly adheres to the sealing surface of the valve 3, sealing the channel connecting the gauge body 1 and the container and preventing a large leakage of the medium inside the container. The openings of the two valves 3 at the upper and lower ends are connected to mating flanges, which are used to connect the gauge body 1 to the corresponding interface on the container, ensuring the sealing and detachability of the connection.

[0039] The outer wall of the gauge body 1 is equipped with a scale, which is set along the axial direction of the gauge body 1 and corresponds one-to-one with the display area of ​​the glass plate. Operators can read the approximate liquid level using the scale, enabling on-site visual observation. The glass plate is located inside the gauge body 1 and communicates with its inner cavity. Both sides of the glass plate are equipped with pressure caps 2, which clamp and fix the glass plate within the gauge body 1. The pressure caps 2 have threaded holes; a bolt is inserted into the threaded hole on one side of the pressure cap 2, and the bolt end passes through the other pressure cap 2 and is threaded to a nut. Tightening the nut presses both pressure caps 2 towards the glass plate, achieving reliable fixation and sealing of the glass plate.

[0040] External valves 5 are connected to both ends of the meter body 1. One of the external valves 5 is connected to one end of the liquid storage tank 6 through a flange. A sealing gasket is provided between the flange and the external valve 5, thereby connecting the liquid storage tank 6 with the inner cavity of the meter body 1, so that the liquid level in the liquid storage tank 6 is consistent with the liquid level in the meter body 1.

[0041] The liquid level detection module 4 consists of capacitive liquid level sensor probes. These probes are evenly spaced along the height of the glass plate, with multiple probes arranged at intervals. The spacing between adjacent probes is determined based on the required measurement accuracy. The capacitive liquid level sensor probes employ a non-contact design, with a capacitor plate installed on the outer wall of the glass tube corresponding to each probe position. Insulating material is used to isolate the capacitor plates from the glass tube to prevent liquid from interfering with the capacitive detection.

[0042] Based on the principle of capacitive sensing, due to the difference in dielectric constant between liquid and air, when the liquid level changes, the capacitance between the liquid-covered capacitor plates and the liquid increases, while the capacitance between the uncovered capacitor plates and the air decreases. The detection circuit determines the liquid level by detecting the changes in capacitance of each capacitor plate. The output of the capacitive liquid level sensor is connected to the microcontroller in the data processing and remote transmission module 7 via a shielded cable. The shielded cable effectively reduces the influence of external electromagnetic interference on the liquid level detection signal. An analog-to-digital converter is installed between the microcontroller and the liquid level sensor. The GPIO pins of the microcontroller are connected to the input of the analog-to-digital converter, which converts the analog signal output by the capacitive liquid level sensor into a digital signal that the microcontroller can process.

[0043] The data processing and remote transmission module 7 includes a microcontroller, an analog-to-digital converter, a filtering circuit, a calibration circuit, and a wireless communication module. The microcontroller uses an STM32 chip as its core processing unit, featuring rich peripheral interfaces and strong data processing capabilities. The microcontroller's SPI master output / slave input pins connect to the wireless communication module's SPI data input pins, and the master input / slave output pins connect to the wireless communication module's SPI data output pins, enabling high-speed data transmission between the microcontroller and the wireless communication module via the SPI interface. The wireless communication module uses a 4G wireless communication module, capable of transmitting data to a remote control center in real time via a 4G network, and also receiving control commands from the remote control center.

[0044] A filter circuit is located at the signal input terminal of the microcontroller. The filter circuit includes resistors and capacitors, which together form a low-pass filter circuit. The cutoff frequency of the low-pass filter circuit is determined by rationally selecting the resistor and capacitor parameters based on the frequency characteristics of the liquid level signal. This ensures that the cutoff frequency is lower than the highest frequency component that may be generated by liquid level changes, effectively filtering out noise components above this frequency and ensuring a stable and reliable liquid level signal input to the microcontroller.

[0045] The calibration circuit is located inside the microcontroller and operates during the equipment installation and commissioning phase. During commissioning, the liquid level in the container is set to multiple known standard heights. The microcontroller records the output value of the capacitive level sensor at each standard height and establishes a calibration curve or calibration formula based on this data. In subsequent operation, the microcontroller corrects the real-time acquired liquid level data according to the calibration curve or calibration formula, improving the accuracy of liquid level measurement.

[0046] The actuator and control module includes a liquid storage tank 6, an electric regulating valve 8, and a diaphragm pump 9. The liquid storage tank 6 is connected to the meter body 1 via an external valve 5 and a flange. The liquid storage tank 6 is installed on the pipe connecting the meter body 1 and the container. The electric regulating valve 8 is installed on the pipe connecting the liquid storage tank 6 and the meter body 1. The electric regulating valve 8 is equipped with a motor driver and a position feedback device. The motor driver is connected to the GPIO pin of the microcontroller. The microcontroller controls the motor driver by outputting PWM signals with different duty cycles. When the PWM signal duty cycle increases, the motor driver drives the motor of the electric regulating valve 8 to rotate forward, increasing the valve opening. When the PWM signal duty cycle decreases, the motor driver drives the motor of the electric regulating valve 8 to rotate in reverse, decreasing the valve opening.

[0047] The position feedback device is a potentiometer. The output signal of the potentiometer is connected to the input pin of the microcontroller. The sliding end of the potentiometer is connected to the valve stem of the electric regulating valve 8. When the valve stem moves, it drives the sliding end of the potentiometer to move, and the resistance value of the potentiometer changes accordingly. It outputs a voltage signal corresponding to the valve opening. The microcontroller acquires the current opening information of the electric regulating valve 8 in real time by collecting this voltage signal, so as to realize closed-loop control of the valve opening.

[0048] A diaphragm pump 9 is connected to the end of the reservoir 6 furthest from the meter body 1. The diaphragm pump 9 is connected to a microcontroller. The reservoir 6 contains a sliding, height-adjustable sealing disc 61. A sliding seal structure is provided between the sealing disc 61 and the inner wall of the reservoir 6 to ensure the sealing disc 61's airtightness during lifting and sliding. The sealing disc 61 divides the interior space of the reservoir 6 into two independent spaces. One independent space is connected to the meter body 1 and is used for liquid storage; the other independent space provides movement space for the sliding of the sealing disc 61 and is connected to the hydraulic interface of the diaphragm pump 9. The GPIO pin of the microcontroller is connected to the negative terminal of the relay coil of the diaphragm pump 9 through a current-limiting resistor. The positive terminal of the relay coil is connected to the positive terminal of the power supply. When the pin outputs a high level, the relay coil is energized, and the diaphragm pump 9 starts; when the pin outputs a low level, the relay coil is de-energized, and the diaphragm pump 9 stops.

[0049] The preset upper and lower liquid level limits are configurable parameters, set remotely by operators through a remote control center according to specific process requirements. Alternatively, they can be pre-written into the microcontroller's storage area during the equipment's factory commissioning phase based on the actual operating conditions of the container. The preset upper liquid level limit is determined by the container's safe maximum liquid level, i.e., the liquid level height between 85% and 95% of the container's total volume. The specific value is determined according to the container's safety design specifications and overflow prevention requirements. The function of the preset upper liquid level limit is to trigger the diaphragm pump 9 to start pumping liquid when the liquid level reaches or exceeds this limit, while simultaneously closing or partially closing the electric regulating valve 8 to prevent the liquid level from continuing to rise and causing the container to overflow. The preset lower liquid level limit is determined by the minimum liquid level required for process operation, i.e., the liquid level height between 15% and 30% of the container's total volume. The specific value is determined according to the minimum operating requirements of the process flow and the requirement to prevent the diaphragm pump 9 from running dry. The function of the preset liquid level lower limit is: when the liquid level drops to or below the lower limit, the diaphragm pump 9 is triggered to start replenishing the liquid, and at the same time the electric regulating valve 8 is opened wide to prevent the liquid level from continuing to drop, which could lead to process interruption or equipment damage.

[0050] When the liquid level exceeds the preset upper limit, the microcontroller controls the diaphragm pump 9 to start. The diaphragm pump 9 draws liquid from the container through the gauge 1 and external valve 5 into the storage space of the storage tank 6. The liquid level in the storage tank 6 rises, and the sealing plate 61 rises accordingly. The volume of the space on the other side of the sealing plate 61 decreases, and the diaphragm pump 9 discharges the gas or liquid in that space. When the liquid level is below the preset lower limit, the microcontroller controls the diaphragm pump 9 to start. The diaphragm pump 9 pumps the solution in the storage space of the storage tank 6 into the container through the external valve 5 and gauge 1. The liquid level in the storage tank 6 drops, and the sealing plate 61 drops accordingly. The volume of the space on the other side of the sealing plate 61 increases, and external liquid or gas is replenished into that space.

[0051] The microcontroller incorporates an adaptive liquid level control algorithm, which uses the rate and magnitude of liquid level change as input parameters; the rate of liquid level change v = , where t n At the current moment, L n For the corresponding liquid level value, t n-1 For the previous moment, L n-1 The liquid level value; the liquid level change range is the difference between the current liquid level value and the set target liquid level value L. target The difference, i.e., the amplitude A=L n- L target .

[0052] In this embodiment, the sampling period T is set to 5 seconds, meaning the microcontroller collects liquid level data and performs an adjustment calculation every 5 seconds. This sampling period is determined based on the typical time constant of liquid level changes. For most industrial container liquid level scenarios, a 5-second sampling period can capture the dynamic changes in liquid level without causing excessively frequent adjustment actions due to overly frequent sampling. Of course, the sampling period T can also be adjusted according to the specific application scenario, ranging from 1 second to 30 seconds.

[0053] The adaptive liquid level control algorithm sets four threshold parameters, which are determined as follows:

[0054] Slow threshold v slow The threshold is set to 0.1 cm / s. This value is determined based on the typical rate of natural fluctuation of liquid level in industrial containers. When the rate of change of liquid level is less than 0.1 cm / s, the liquid level is considered to be in a state of natural, slow change. (Rapid threshold v) fast The threshold is set to 1.0 cm / s. When the liquid level change rate exceeds 1.0 cm / s, it is considered to be in a state of rapid change, requiring a rapid response. Small amplitude threshold A. small The threshold is set to 2cm. When the absolute value of the deviation between the liquid level and the target value is less than 2cm, the deviation is considered small and requires fine adjustment. Large amplitude threshold A. large The setting is 10cm. When the absolute value of the deviation between the liquid level and the target value is greater than 10cm, it is considered that the deviation is too large and a coarse adjustment is required to quickly pull back.

[0055] In this embodiment, the minimum adjustment amount D min The PWM duty cycle is set to 2%, meaning that the change in the opening of the electric regulating valve 8 each time it is adjusted will not exceed 2% of the current opening. Maximum adjustment amount D max The PWM duty cycle is set to 15%, meaning that the change in the opening of the electric regulating valve 8 each time it is adjusted will not exceed 15% of the current opening. min and D max The value of D is determined by combining the full stroke time of the electric regulating valve 8 and the maximum allowable regulating rate of the process. min An excessively large value (D) will cause the liquid level to oscillate around the target value. max Too small a value will result in a slow adjustment response. The value used in this embodiment has been verified through actual debugging and can achieve a good balance between adjustment accuracy and response speed.

[0056] The control logic of the adaptive liquid level regulation algorithm is divided into three regions:

[0057] The first region is the fine-tuning zone. When the rate of change in liquid level, v, is less than the slow threshold, v... slow Furthermore, the absolute value of the liquid level change amplitude A is less than the small amplitude threshold A. smallThis indicates that the liquid level fluctuation is small and changes slowly, indicating that it is in the fine-tuning stage near the target value. The algorithm selects the minimum adjustment amount D. min This is used to adjust the PWM duty cycle. The adjustment direction is determined by the sign of the amplitude A: when A is greater than zero, i.e., the liquid level is higher than the target value, the PWM duty cycle is decreased by D. min This causes the electric regulating valve 8 to close slightly, reducing the liquid inflow; when A is less than zero, i.e., the liquid level is below the target value, the PWM duty cycle increases. min This causes the electric regulating valve 8 to open wider, increasing the liquid inlet flow.

[0058] The second region is the coarse adjustment zone. When the rate of change in liquid level v is greater than the rapid threshold v... fast Or the absolute value of the liquid level change amplitude A is greater than the large amplitude threshold A. large This indicates that the liquid level is fluctuating significantly or deviating far from the target value, requiring a rapid response. The algorithm selects the maximum adjustment amount D. max This is used to adjust the PWM duty cycle. The adjustment direction is also determined by the sign of the amplitude A: when A is greater than zero, the PWM duty cycle decreases by D. max This causes the electric regulating valve 8 to close quickly; when A is less than zero, the PWM duty cycle increases. max This causes the electric regulating valve 8 to open rapidly.

[0059] The third zone is the normal adjustment zone. When the rate of change in liquid level v is greater than or equal to the slow threshold v... slow And less than or equal to the fast threshold v fast And the absolute value of the liquid level change amplitude A is greater than or equal to the small amplitude threshold A. small And less than or equal to the large threshold A large This indicates that the liquid level is in a state of moderate change. The algorithm selects a moderate adjustment amount D. mid As the adjustment amount for the PWM duty cycle in this operation, D mid Equals D min With D max The average value is 8.5% of the PWM duty cycle. The adjustment direction is determined by the sign of the amplitude A.

[0060] The following section uses specific numerical examples to illustrate the algorithm's execution process. The target liquid level value L is set. target The current sampling time is t, and the current sampling time is 50cm. n liquid level L n The value is 55cm, and the previous sampling time t n-1 liquid level L n-1 The sample depth is 53 cm, and the sampling period T is 5 seconds. Therefore, the rate of change of liquid level v is equal to the difference between 55 and 53 divided by 5, which is 0.4 cm / s. The amplitude of the change in liquid level A is equal to 55 minus 50, which is 5 cm, and the absolute value of A is 5 cm.

[0061] Comparing the relationship between each parameter and the threshold: v equals 0.4 cm / s, which is greater than the slow threshold v. slow That is, 0.1 cm / s, and less than the fast threshold v. fast That is, 1.0 cm / s; the absolute value of A is equal to 5 cm, which is greater than the small amplitude threshold A. small That is, 2cm, and less than the large amplitude threshold A. large That is, 10cm. Therefore, the current state falls into the third region, which is the normal adjustment zone. Since A is greater than zero, it indicates that the liquid level is higher than the target value, and the valve needs to be closed slightly. The algorithm selects a medium adjustment amount D. mid That is, 8.5%, the PWM duty cycle is reduced by 8.5% from the current value, driving the electric regulating valve 8 to close less, causing the liquid level to drop.

[0062] If under the same operating conditions, at the previous time t n-1 liquid level L n-1 If the value is 48cm instead of 53cm, then v equals the difference between 55 and 48 divided by 5, which is 1.4cm / s. v is greater than the fast threshold v. fast That is, 1.0 cm / s. At this point, it falls into the second region, which is the coarse adjustment zone. The algorithm selects the maximum adjustment amount D. max That is, 15%, the PWM duty cycle is reduced by 15% from the current value, the electric regulating valve 8 is quickly closed, and the liquid level drops rapidly.

[0063] If under the same operating conditions, at the previous time t n-1 liquid level L n-1 If the velocity is 54.5 cm, then v equals the difference between 55 and 54.5 divided by 5, which is 0.1 cm / s. v is equal to the slow threshold v. slow And the absolute value of A is 5cm, which is between A and B. small and A large Between these points, if the price falls into the third zone, i.e., the conventional adjustment zone, then a moderate adjustment amount D should still be selected. mid If L n-1 If the velocity is 54.9 cm, then v equals 0.02 cm / s, which is less than the slow speed threshold v. slow And the absolute value of A is 5cm, which is greater than A. small At this point, the dual conditions of the first region are not met, and it still falls into the third region. If L n The absolute value of A is 1 cm, which is 51 cm, and is less than A. small And v is 0.02cm / s, which is less than v slow If it falls into the first region, i.e., the fine-tuning region, then the minimum adjustment amount D is selected. min That is, a 2% fine-tuning.

[0064] The adaptive liquid level control algorithm is programmed internally by the microcontroller. The microcontroller uses a timer to precisely obtain the sampling period T and acquires data from the capacitive liquid level sensor via an analog-to-digital converter interface to obtain the liquid level value L. n Read the liquid level value L from the internal storage area of ​​the previous sampling period. n-1 Calculate the rate of change of liquid level v and amplitude A, compare v and A with four preset thresholds to determine the current region, and select the corresponding adjustment amount D according to the region. min D mid Or D max The adjustment direction is determined by the sign of the amplitude A, and the target PWM duty cycle is calculated. The microcontroller outputs the adjusted PWM signal to the motor driver of the electric regulating valve 8 through the GPIO pin. The processing core of the microcontroller performs real-time analysis and processing of the collected data according to the above rules, and performs an adjustment calculation once in each sampling cycle to achieve adaptive adjustment of the liquid level.

[0065] During operation, the capacitive level sensor probe of the level detection module 4 continuously monitors the liquid level along the height of the glass plate. The difference in dielectric constant between the liquid and air results in varying capacitance values ​​for each probe. The detection circuit converts these capacitance changes into an analog electrical signal. This signal is transmitted via a shielded cable to an analog-to-digital converter (ADC), which converts it into a digital signal. The digital signal is then filtered by a low-pass filter to remove high-frequency noise before being sent to the microcontroller. The microcontroller calibrates and corrects the digital signal according to a calibration curve to obtain the accurate current liquid level value L. n Simultaneously read the liquid level value L stored in the previous sampling period. n-1 Combined with the time interval tn recorded by the timer, minus t n-1 The liquid level change rate v and amplitude A are calculated, and v and A are input into the adaptive liquid level regulation algorithm. The algorithm determines the PWM duty cycle adjustment amount for this adjustment based on the relationship between v and A. The microcontroller outputs the adjusted PWM signal to the motor driver of the electric regulating valve 8. The motor driver drives the electric regulating valve 8 to move to the target opening. The potentiometer feeds back the actual valve opening to the microcontroller. The microcontroller compares the target opening with the actual opening. If there is a deviation, it continues to adjust the PWM signal until the actual opening matches the target opening.

[0066] Meanwhile, the microcontroller transmits the calibrated liquid level data to the 4G wireless communication module via the SPI interface. The 4G wireless communication module then uploads the liquid level data to the remote control center in real time via the 4G network. Operators can view the current liquid level, liquid level trend, opening degree of the electric regulating valve 8, and operating status of the diaphragm pump 9 in real time on the monitoring interface of the remote control center. They can also issue control commands through the remote control center. Upon receiving the remote control commands, the microcontroller combines the adaptive liquid level adjustment algorithm with preset upper and lower liquid level limits to comprehensively control the actions of the electric regulating valve 8 and the diaphragm pump 9.

[0067] When the microcontroller determines that the liquid level exceeds the preset upper limit, it outputs a control signal to start the diaphragm pump 9. The diaphragm pump 9 draws liquid from the container through the gauge 1 and external valve 5 into the storage space of the storage tank 6, causing the liquid level in the storage tank 6 to rise. The sealing plate 61 rises accordingly, and the volume of the space on the other side of the sealing plate 61 decreases, thus lowering the liquid level. When the microcontroller determines that the liquid level is below the preset lower limit, it outputs a control signal to start the diaphragm pump 9. The diaphragm pump 9 pumps the solution from the storage space of the storage tank 6 into the container through the external valve 5 and gauge 1, causing the liquid level in the storage tank 6 to drop. The sealing plate 61 drops accordingly, and the volume of the space on the other side of the sealing plate 61 increases, thus raising the liquid level. During the liquid level adjustment process, when the liquid level is between the preset upper and lower limits, the microcontroller only adjusts the level through the electric regulating valve 8, and the diaphragm pump 9 does not operate. When the liquid level reaches or exceeds the preset upper limit, or drops to or falls below the preset lower limit, the microcontroller starts the diaphragm pump 9 for coarse adjustment, and the electric regulating valve 8 operates simultaneously. The electric regulating valve 8 performs fine adjustment based on the output of the adaptive liquid level regulation algorithm under all operating conditions, while the diaphragm pump 9 only intervenes to perform coarse adjustment when the liquid level exceeds the preset upper and lower limits. The two work together to achieve rapid, stable and precise control of the liquid level.

[0068] Throughout the entire operation, the safety steel balls inside valves 3 at both ends of gauge body 1 are always under monitoring. If the glass plate unexpectedly breaks, the pressure inside the container immediately pushes the safety steel balls to seal the passage, preventing media leakage and ensuring the safety of equipment and personnel. Operators can also visually observe the gauge scale on the outer wall of gauge body 1 and the glass plate, serving as a supplement and verification method to the electronic monitoring.

[0069] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A glass plate level gauge capable of remote control, comprising a gauge body (1) and a glass plate, characterized in that, It also includes a liquid level detection module (4), whose probes are evenly spaced along the height direction of the glass plate and are used to measure the liquid level height; The data processing and remote transmission module (7) includes a microcontroller and a wireless communication module integrated on the microcontroller. The microcontroller is connected to the liquid level detection module (4) to preprocess the liquid level data and transmit the processed liquid level data to the remote control center in real time through the wireless communication module. The actuator and control module include an electric regulating valve (8) installed on the pipeline connecting the liquid storage tank (6) and the meter body (1) in communication with the meter body (1). The data processing and remote transmission module (7) is installed on the outer wall of the liquid storage tank (6). The electric regulating valve (8) is connected to the microcontroller. The microcontroller controls the opening of the electric regulating valve (8) according to the remote control command and the preset upper and lower limits of the liquid level, thereby adjusting the liquid level height. It also includes a diaphragm pump (9) connected to the end of the reservoir (6) away from the body (1), the diaphragm pump (9) being connected to a microcontroller, the reservoir (6) having a built-in lifting and sliding sealing disc (61), the sealing disc (61) dividing the space inside the reservoir (6) into two independent spaces; The microcontroller has a built-in adaptive liquid level adjustment algorithm, which can automatically adjust the control parameters of the electric regulating valve (8) according to the speed and magnitude of the liquid level change.

2. The glass plate level gauge capable of remote control according to claim 1, characterized in that, The upper and lower ends of the instrument body (1) are connected to valves (3), and the valves (3) are equipped with safety steel balls. When the glass plate breaks, the safety steel balls block the channel connecting the instrument body (1) and the container under the pressure inside the container. The two valves (3) at the top and bottom ends are connected to mating flanges at their openings.

3. A glass plate level gauge capable of remote control according to claim 2, characterized in that, The outer wall of the watch body (1) is provided with a scale, which is set along the axial direction of the watch body (1) and corresponds to the display area of ​​the glass plate; The glass plate is disposed inside the watch body (1) and communicates with the inner cavity of the watch body (1). Both sides of the glass plate are provided with pressure caps (2) to clamp and fix the glass plate inside the watch body (1). The pressure cap (2) has a threaded hole, and a bolt is inserted through the threaded hole of one side of the pressure cap (2), and the end of the bolt passes through the other side of the pressure cap (2) and is threaded to a nut.

4. A glass plate level gauge capable of remote control according to claim 3, characterized in that, The two ends of the meter body (1) are also connected to external valves (5), one of which is connected to one end of the liquid storage tank (6) through a flange, thereby connecting the liquid storage tank (6) with the inner cavity of the meter body (1).

5. A glass plate level gauge capable of remote control according to claim 1, characterized in that, The liquid level detection module (4) is a capacitive liquid level sensor probe. The output end of the capacitive liquid level sensor is connected to the general input / output pin of the microcontroller through a shielded cable. An analog-to-digital converter is set between the microcontroller and the liquid level sensor. The GPIO pin of the microcontroller is connected to the input end of the analog-to-digital converter.

6. A glass plate level gauge capable of remote control according to claim 1, characterized in that, The microcontroller's SPI Master Output Slave Input (MOSI) pin is connected to the SPI data input pin of the wireless communication module, and its Master Input Slave Output (MISO) pin is connected to the SPI data output pin of the wireless communication module.

7. A glass plate level gauge capable of remote control according to claim 1, characterized in that, The microcontroller signal input terminal is equipped with a filtering circuit, which includes resistors and capacitors to form a low-pass filter circuit. The low-pass filter circuit selects resistor and capacitor parameters reasonably according to the frequency characteristics of the liquid level signal so that the cutoff frequency can effectively filter out noise components higher than the liquid level signal frequency.

8. A glass plate level gauge capable of remote control according to claim 1, characterized in that, The electric regulating valve (8) is equipped with a motor driver and a position feedback device. The motor driver is connected to the GPIO pin of the microcontroller. The microcontroller controls the motor driver by outputting pulse width modulation (PWM) signals with different duty cycles, thereby driving the opening of the electric regulating valve (8). The position feedback device of the electric regulating valve (8) is a potentiometer. The output signal of the potentiometer is connected to the input pin of the microcontroller. The sliding end of the potentiometer is connected to the valve stem of the electric regulating valve (8). When the valve stem moves, the resistance value of the potentiometer changes and outputs a voltage signal corresponding to the opening degree of the valve (3). The microcontroller collects the voltage signal and obtains the current opening degree information of the electric regulating valve (8) in real time.

9. A glass plate level gauge capable of remote control according to claim 1, characterized in that, The adaptive liquid level regulation algorithm uses the rate and magnitude of liquid level change as input parameters; Liquid level change rate v= , where t n At the current moment, L n For the corresponding liquid level value, t n-1 For the previous moment, L n-1 This refers to the liquid level value. The liquid level change range is the difference between the current liquid level value and the set target liquid level value L. target The difference, i.e., the amplitude A=L n -L target .

10. A glass plate level gauge capable of remote control according to claim 1, characterized in that, The GPIO pin of the microcontroller is connected to the negative terminal of the relay coil of the diaphragm pump (9) through a current-limiting resistor, and the positive terminal of the relay coil is connected to the positive terminal of the power supply; this pin will be used to output signals to control the start and stop of the diaphragm pump (9); One of the independent spaces is used for liquid storage, and the other independent space provides space for the lifting and sliding of the sealing disc (61) and is connected to the hydraulic interface of the diaphragm pump (9); When the liquid level exceeds the preset upper limit, the diaphragm pump (9) draws the liquid in the container into the storage tank (6). When the liquid level is lower than the preset lower limit, the diaphragm pump (9) pumps the solution in the storage tank (6) into the container.

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