Batch calibration tool for sensor components of gas detector

Abstract

The utility model provides a batch calibration tool for gas detector sensor components, and mainly relates to the technical field of gas detector production. The batch calibration tool for the gas detector sensor components comprises an insulating plate, a plurality of through holes are formed in the insulating plate, positioning grooves are formed in the through holes, sensor mounting seats are mounted in the through holes, a plurality of ventilation holes are formed in the insulating plate, a power supply communication plate is arranged on one side of the insulating plate, and the power supply communication plate is arranged on the other side of the insulating plate. The upper portion of the sensor mounting seat is provided with an upper end face, the lower portion of the sensor mounting seat is provided with a lower end face, and reinforcing ribs are arranged outside the sensor mounting seat and matched with the positioning grooves. The beneficial effects of the gas alarm calibration device are that the gas alarm calibration device can efficiently and accurately calibrate gas alarms in batches through the structure on the insulating plate, the sensor mounting seat and other structures.

Description

Technical Field

[0001] This utility model mainly relates to the field of gas detector manufacturing technology, specifically a batch calibration fixture for gas detector sensor components. Background Technology

[0002] Gas is becoming increasingly common, but accidents are also on the rise. This has led to a growing need for gas alarms. For alarm manufacturers, improving production efficiency while ensuring product quality is becoming increasingly important.

[0003] Gas detectors used in industrial and commercial applications typically employ explosion-proof designs due to the explosion-proof requirements of their operating environments. However, explosion-proof structures are generally bulky and, constrained by the available space, contain multiple circuit boards connected via connectors or wires to achieve different functionalities. This necessitates significant manual labor in the manufacturing process, hindering production efficiency. Furthermore, the gas calibration process limits production to a small quantity each time, leading to technical variations between different batches.

[0004] To improve production efficiency, detectors can adopt a modular design to facilitate independent production or on-site component replacement, especially for sensor components. Because some sensors have a short lifespan, or when sensor components fail, there is a need to replace them in the field. The replacement sensor components must be compatible with other circuits, and recalibration in the field should be avoided as much as possible. Therefore, new demands are placed on the design and manufacturing of sensor components. Utility Model Content

[0005] To address the shortcomings of existing technologies, this utility model provides a batch calibration fixture for gas detector sensor components. It calibrates gas alarms efficiently and accurately in batches through structures such as the insulating plate structure and sensor mounting base.

[0006] To achieve the above objectives, this utility model employs the following technical solution:

[0007] A batch calibration fixture for a gas detector sensor component includes an insulating plate with several through holes and positioning grooves in the through holes. A sensor mounting base is installed in each through hole. Several ventilation holes are also provided on the insulating plate. A power supply and communication board is provided on one side of the insulating plate. The sensor mounting base has an upper end face and a lower end face. The sensor mounting base has reinforcing ribs on its exterior, which are adapted to the positioning grooves.

[0008] The insulating board has handles on both sides.

[0009] The power supply and communication board is equipped with a wire harness interface, a power indicator light, and a power switch.

[0010] The insulation plate is provided with a plurality of support leg mounting holes.

[0011] The insulation plate is provided with a plurality of wire bundle holes.

[0012] Compared with the prior art, the utility model has the beneficial effects that:

[0013] 1. Multiple (96 in the example) sensor components can be produced each time, greatly improving the production efficiency of the sensor components, and further improving the production efficiency of the explosion-proof detector, ensuring the consistency of a batch, and reducing gas emission during the production process;

[0014] 2. Centralized turnover improves turnover efficiency;

[0015] 3. Layered placement improves the use efficiency of space;

[0016] 4. Multiple air holes are conducive to uniform distribution of gas;

[0017] 5. Monitoring the power supply of each sensor component facilitates timely detection of abnormalities in the measured product;

[0018] 6. The structured sensor mounting seat facilitates quick placement of the sensor component, is stable after placement, and also plays a protective role;

[0019] 7. The upper end surface of the sensor mounting seat and the reinforcing ribs can facilitate quick replacement of the sensor mounting seat and prevent it from rotating and moving randomly. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 is the insulation plate structure schematic view of the utility model;

[0021] Figure 2 is the sensor mounting seat first visual angle structure schematic view of the utility model;

[0022] Figure 3 is the sensor mounting seat second visual angle structure schematic view of the utility model;

[0023] Figure 4 is the electrical principle view of the utility model;

[0024] Figure 5 is the power supply communication board structure schematic view of the utility model.

[0025] The labels shown in the drawings: 1, insulating plate; 2, sensor mounting seat; 10, through hole; 11, ventilation hole; 12, power supply communication board; 13, handle; 14, support leg mounting hole; 15, wire harness hole; 21, upper end face; 22, lower end face; 23, reinforcing rib; 100, positioning groove; 121, wire harness interface; 122, power indicator; 123, power switch. DETAILED DESCRIPTION

[0026] The utility model will be further explained in connection with the drawings and specific embodiments. It should be understood that these embodiments are only used for explaining the utility model and are not used for limiting the scope of the utility model. In addition, it should be understood that after reading the content taught by the utility model, those skilled in the art can make various changes or modifications to the utility model, and these equivalent forms also fall within the scope defined by the present application.

[0027] In connection with the drawings Figures 1-5 A kind of batch calibration tool of gas detector sensor component, including insulating plate 1, several through holes 10 are set in the insulating plate 1, positioning groove 100 is set in the through hole 10, sensor mounting seat 2 is installed in the through hole 10, several ventilation holes 11 are set in the insulating plate 1, power supply communication board 12 is equipped on one side of the insulating plate 1, the upper end face 21 is formed in the upper portion of the sensor mounting seat 2, the lower end face 22 is formed in the lower portion of the sensor mounting seat 2, the reinforcing rib 23 is formed in the outer portion of the sensor mounting seat 2, the reinforcing rib 23 is adapted to positioning groove 100.The lower portion of the upper end face 21 is attached to the surface of the insulating plate 1, the upper portion of the lower end face 22 is attached to the sensor of gas detector, the reinforcing rib 23 can improve the strength of the sensor mounting seat 2 while realizing the positioning of the sensor mounting seat 2 on the insulating plate 1.There is a circuit for powering and communicating with sensor component on the insulating plate 1, which facilitates communication with the tested sensor component and reads the parameters of the production process.

[0028] The two sides of the insulating plate 1 are provided with handles 13; the handle 13 is a support for horizontal placement, and the purpose of the support is to prevent the sensor component from contacting the desktop or other flat surfaces. The support can be telescopic to minimize the space occupied when the tool plate is not in use. When in use, the tool plates can be stacked to reduce the floor space and improve the space utilization.

[0029] The power supply communication board 12 is provided with a wire harness interface 121, a power indicator 122 and a power switch 123; the wire harness interface 121 is used to connect the sensing component, the power indicator 122 is used to indicate the state of the sensing component, and the power supply communication board 12 can monitor the power supply voltage and current of each sensing component; the connection communication circuit of the power supply communication board 12 and the sensing component is as shown in Figure 4 The structure of the power supply communication board 12 is as shown in Figure 5Power switch, individually control the power supply of each column on the tooling plate, facilitate the observation of each measured sensor component for abnormalities when manually placing the measured sensor component, so as to timely dispose.

[0030] The insulating plate 1 is provided with a plurality of support leg mounting holes 14.

[0031] The insulating plate 1 is provided with a plurality of wire harness holes 15. Figure 1 The holes marked X01-X24 shown; for passing through the sensor output wire harness; the output wire harness of the sensor component, plugged into the circuit of the tooling insulating plate 1, to complete the interface of power supply and communication; one end of the wire harness is in the terminal block, and the other end is in the upper left corner or the upper right corner of the sensor seat, and is passed through the wire harness hole, which also plays a role in fixing the wire harness.

[0032] The insulating plate 1 can be made of electrician's bakelite or epoxy plate, and has certain strength. The number of through holes 10 is determined according to the size of the aeration tank, for example, 4x6. The remaining space of the insulating plate 1 is also provided with a plurality of ventilation holes 11, which facilitates the sensor to apply gas in the aeration calibration tank, so that the gas forms convection in the aeration tank, and the test gas is uniformly distributed.

[0033] Power supply circuit: the power supply adopts direct current 24V, and has a plurality of DC / DC converters inside, which generates a plurality of direct current 5V, which is used to supply power to the measured sensor component, reduces the current of the primary power supply, and each DC / DC has an overcurrent protection function and an independent power switch 123.

[0034] Communication circuit: the serial communication ports of the 4x6 measured sensor components in the example are connected together, and are uniformly managed by the MCU. The MCU has another external serial communication, which facilitates the output of the information of all measured sensor components to the tooling controller, so as to issue operation instructions according to the production process, or read parameters for display.

[0035] Other circuit functions of the power supply and communication board:

[0036] 1) Display the current of each direct current 5V, which is convenient for understanding the working condition of the measured sensor component;

[0037] 2) Measure and display the temperature and humidity in the current environment, which is convenient for the tooling controller to record the environmental condition at the time of production, so as to trace back;

[0038] Use of the tooling plate:

[0039] 1. Place the measured sensor component in the sensor mounting seat 2 of the tooling insulating plate one by one;

[0040] 2, The output lead of the sensor component is connected with the wire harness in the corresponding position of the fixture plate;

[0041] 3, The fixture insulation plate is connected with the fixture controller and the external power supply;

[0042] 4, Turn on the power switch on the insulation plate one by one to energize the sensor component;

[0043] 5, Observe the power supply current of each path to ensure that all measured sensor components are in normal working condition;

[0044] 6, Move the fixture and sensor to the gas filling tank and energize for a period of time;

[0045] 7, One gas filling tank can place four fixture plates;

[0046] 8, According to the production process, inject a certain concentration of gas in the gas filling tank, issue control instructions through the fixture controller, and record the current calibration data of the sensor component;

[0047] 9, Repeat adding the required concentration of gas according to the process to realize multi-point calibration;

[0048] 10, After all the calibration is completed, remove the gas in the gas filling tank and run in air for a period of time;

[0049] 11, Then repeat injecting a certain concentration of gas, check the data detected by the sensor component, and perform error analysis to determine whether it is qualified;

[0050] 12, After detecting multiple concentration points, remove the gas in the gas filling tank and transfer the fixture plate to the subsequent production process.

[0051] The device can be applied to sensors of different technical principles to detect different types of gases, even toxic and harmful gases such as hydrogen sulfide, sulfur dioxide, ammonia, chlorine, carbon monoxide, etc., greatly improving the utilization rate of production equipment and the production quality of products.

[0052] The sensor is used to detect different gases, and its detection principle includes semiconductor type, catalytic combustion type, electrochemical type, infrared type, laser type, etc. Different sensors have different processing circuits, but their essence is the same, that is, converting the gas concentration signal into an electrical signal, which is processed by the processor MCU and then converted into a digital serial communication, which unifies different principle sensors.

[0053] The production fixture using the patent technology requires that the sensor component has the following technical features:

[0054] 1, The external physical interface is unified, using a 2.54 pitch TJ-4P plug;

[0055] 2. Unified external electrical interface, 5V, GND, TXD, RXD, i.e. 5V power supply, TTL serial interface;

[0056] 3. Unified communication protocol;

[0057] 4. Unified appearance, outer diameter 30mm;

[0058] The following is a brief introduction to the sensor component:

[0059] Power supply circuit, the power supply voltage required by different sensors is not the same, the power supply voltage of the sensor component is planned to be unified DC 5V, and different LDO outputs are used inside to match the voltage of the sensor circuit. The use of LDO ensures the stability of the internal voltage when the external input power supply changes.

[0060] Processor MCU, collects the voltage signal after the sensor is processed by the processing circuit, converts it into digital output according to the characteristics of the sensor, and can store operating parameters to realize related calculation and compensation.

[0061] Communication interface, using TTL serial port, with unified communication protocol; the level is unified to DC 5V, so as to unify the electrical interface, and TJ-4P plug is used externally.

[0062] Through the above design, due to the use of unified structure size, unified electrical interface and unified software protocol, the sensor component can be independently produced and calibrated, and can be matched with any planned detector, and can be produced using the tool.

[0063] The important process of gas detector production is calibration and retest.

[0064] Calibration, according to the predetermined production process, a fixed concentration of gas is applied to the sensor, and the corresponding voltage value is recorded by the sensor, which is used as the operating parameter and is corrected.

[0065] Re-test, test whether the detector reaches the expected gas detection effect, simply speaking, it is to verify whether the detection error of the detector is within the standard specified range.

[0066] The calibration and retest process must apply a predetermined concentration of gas to the detector. Due to the large size and bulkiness of the explosion-proof detector, the production efficiency is restricted. According to the circuit characteristics of the detector, the circuit used for control and display at the back end is simple in production process and can be independently produced. The sensor component needs to be applied with the process characteristics of the gas, and a special tool is customized to realize batch rapid production.

[0067] Finally, it should be noted that: the above examples are used to illustrate the technical solutions of the present application, but not limited to; although the present application is described in detail with reference to the foregoing examples, those skilled in the art should understand that: it can still be modified to the technical solutions recorded in the foregoing examples, or part of the technical features are replaced; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A batch calibration tool for a gas detector sensor component, comprising an insulating plate (1), characterized in that: The insulating plate (1) is provided with a plurality of through holes (10), the through holes (10) are provided with positioning grooves (100), the through holes (10) are provided with sensor mounting seats (2), the insulating plate (1) is provided with a plurality of ventilation holes (11), one side of the insulating plate (1) is provided with a power supply communication plate (12), the upper part of the sensor mounting seat (2) is provided with an upper end face (21), the lower part of the sensor mounting seat (2) is provided with a lower end face (22), the outer part of the sensor mounting seat (2) is provided with reinforcing ribs (23), and the reinforcing ribs (23) are adapted to the positioning grooves (100).

2. A batch calibration tool for a gas detector sensor component according to claim 1, wherein: Both sides of the insulating plate (1) are provided with handles (13).

3. A batch calibration tool for a gas detector sensor component according to claim 1, wherein: The power supply communication plate (12) is provided with a wire harness interface (121), a power indicator (122) and a power switch (123).

4. A batch calibration tool for a gas detector sensor component according to claim 1, wherein: The insulating plate (1) is provided with a plurality of support leg mounting holes (14).

5. A batch calibration tool for a gas detector sensor component according to claim 1, wherein: The insulating plate (1) is provided with a plurality of wire harness holes (15).

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