Contactless water level automatic control system

Abstract

The utility model relates to a contactless automatic water level control system, which is applied to the technical field of water supply and drainage, and comprises a foam rod serving as a water level sensing element according to the characteristic that the density of the foam rod is far smaller than that of water, and the foam rod can move up and down along with water under the action of buoyancy when the water level changes. The displacement change of the foam rod is highly consistent with the water level change; an infrared sensor is arranged to monitor the height of a foam rod, when the foam rod is located at the initial position, part of infrared rays are reflected back to a receiving end by the foam rod, when the water level rises or falls, the position of the foam rod is changed, the intensity of the infrared rays reflected back to the receiving end is also changed, and the infrared sensor monitors the height of the foam rod according to the intensity change of the received infrared rays. The electric signal is output, so that the water level change is detected; and the MCU controller outputs high-low level signals to the alternating current contactor according to the electric signals, so as to control the start and stop of the water pump.

Description

TECHNICAL FIELD

[0001] The utility model relates to water supply and drainage technical field, concretely relates to a non-contact water level automatic control system. BACKGROUND

[0002] In the yarn steaming process of the textile industry, the yarn steaming pot vacuum pump is responsible for extracting air in the pot to create a vacuum environment to ensure that steam can fully penetrate into the yarn, so that the yarn achieves better setting, softness and moisture regain effect. During the intermittent vacuum drainage stage of the vacuum pump, the relatively large pressure generated will cause great impact on the water level control device.

[0003] The traditional water level control float ball is usually made of plastic or metal material, and its mechanical structure is particularly fragile when facing the high-pressure water flow impact of the yarn steaming pot vacuum pump drainage. The strong impact force generated during the drainage process can easily cause the connecting parts of the float ball to loosen and fall off, or directly cause the float ball body to break. Therefore, the traditional water level control float ball is prone to failure when facing such harsh working conditions. Once the float ball is damaged, it cannot accurately sense the water level change, and the water pump cannot work normally according to the set water level. When the water level is lower than the normal working water level, the water pump will continue to run but there is no water to extract, i.e. dry pumping occurs. This not only causes the mechanical parts of the water pump to be severely worn due to lack of liquid lubrication, but also causes the current of the motor winding to rise sharply, resulting in overheating of the motor and ultimately causing the water pump to burn out. At the same time, the traditional water level control float ball moves up and down with the water level relying on its own buoyancy, and triggers the micro switch through the mechanical linkage mechanism to control the start and stop of the water pump. However, this control method has a large hysteresis and error. When the water level changes rapidly, the response speed of the float ball movement cannot keep up with the water level change speed, resulting in untimely start and stop of the water pump. SUMMARY

[0004] Therefore, the purpose of the utility model is to provide a non-contact water level automatic control system to solve the problems in the prior art that the water level control float ball is prone to failure when facing high-pressure water flow impact, cannot accurately sense the water level change, and the water pump is easily damaged. At the same time, it solves the problem that the traditional water level control float ball moves up and down with the water level relying on its own buoyancy, triggers the micro switch through the mechanical linkage mechanism to control the start and stop of the water pump, has a large hysteresis and error, and when the water level changes rapidly, the response speed of the float ball movement cannot keep up with the water level change speed, resulting in untimely start and stop of the water pump.

[0005] The utility model provides a non-contact water level automatic control system, the system includes:

[0006] Foam stick: arranged in the yarn steaming pot and floating up and down with the change of the water level in the yarn steaming pot;

[0007] Infrared sensor: including a transmitting end and a receiving end;

[0008] The emitting end is used for continuously emitting infrared rays to irradiate the top of the foam stick at a preset angle; in the initial state of the water level in the steaming pot, part of the infrared rays emitted by the emitting end is reflected back to the receiving end of the infrared sensor by the foam stick;

[0009] The receiving end is used for receiving the infrared rays reflected by the foam stick, and the intensity of the infrared rays received by the receiving end changes with the up-and-down floating of the foam stick;

[0010] The infrared sensor converts the intensity of the infrared rays received by the receiving end into an electric signal and sends the electric signal to the MCU controller;

[0011] The MCU controller is used for receiving the electric signal sent by the infrared sensor and outputting a high-level signal or a low-level signal to the AC contactor according to the electric signal;

[0012] The AC contactor is used for closing the main contact when receiving the high-level signal, so that the water pump starts to pump water from the steaming pot; and the AC contactor is also used for opening the main contact when receiving the low-level signal, so that the water pump stops pumping water from the steaming pot.

[0013] Preferably, the system further comprises:

[0014] A PVC plastic pipe network;

[0015] A small hole with a certain diameter is arranged on the PVC plastic pipe network at a preset interval, so as to ensure that water can freely enter and exit the PVC plastic pipe network;

[0016] The foam stick is arranged in the PVC plastic pipe network, and the foam stick floats up and down in the PVC plastic pipe network according to the change of the water level in the steaming pot.

[0017] Preferably,

[0018] The top and the bottom of the PVC plastic pipe network are respectively provided with a support and a sealing joint;

[0019] The infrared sensor is fixed above the PVC plastic pipe network through a matching support;

[0020] The PVC plastic pipe network is fixed at the drain port of the steaming pot.

[0021] Preferably,

[0022] The MCU controller outputs a high-level signal or a low-level signal to the AC contactor according to the electric signal includes:

[0023] The MCU controller is preset with an electric signal corresponding to an upper limit water level and an electric signal corresponding to a lower limit water level;

[0024] The MCU controller sends a high-level signal to the AC contactor when detecting that the water level rises to the set upper limit water level according to the electric signal sent by the infrared sensor.

[0025] Preferably, further comprising:

[0026] The signal indicator light;

[0027] The signal indicator light is electrically connected with the MCU controller;

[0028] The signal indicator light comprises red and green;

[0029] The signal indicator light is green in normal state, and the signal indicator light is red when receiving the control signal from the MCU controller.

[0030] Preferably, further comprising:

[0031] The display screen;

[0032] The display screen is electrically connected with the MCU controller;

[0033] The MCU controller converts the electric signal sent by the infrared sensor into a digital signal and sends the digital signal to the display screen, and the display screen displays the water level height according to the digital signal.

[0034] Preferably, further comprising:

[0035] The transparent plastic pipe;

[0036] The connection line between the infrared sensor and the MCU controller is arranged in the transparent plastic pipe.

[0037] The technical scheme provided by the embodiment of the utility model can have the following beneficial effects:

[0038] The application utilizes the characteristic that the density of the foam stick is far less than that of water, and uses the foam stick as a water level sensing element. When the water level changes, the foam stick will move up and down with the water body under the action of buoyancy, and the displacement change of the foam stick is highly consistent with the water level change. An infrared sensor is arranged to monitor the height of the foam stick. When the foam stick is at the initial position, part of the infrared rays is reflected back to the receiving end by the foam stick. When the water level rises or falls, the position of the foam stick changes, and the intensity of the infrared rays reflected back to the receiving end also changes. The infrared sensor converts the change of the received infrared intensity into an electric signal output, so as to realize the detection of the water level change. The MCU controller outputs a high or low level signal to the AC contactor according to the electric signal, so as to control the start and stop of the water pump.

[0039] It should be understood that the foregoing general description and the following detailed description are only exemplary and explanatory, and cannot limit the application. BRIEF DESCRIPTION OF DRAWINGS

[0040] The drawings incorporated into the specification and constituting a part of the specification show embodiments consistent with the present application and, together with the specification, serve to explain the principles of the present application.

[0041] Figure 1 is a whole system schematic diagram of a non-contact water level automatic control system according to an exemplary embodiment, and the system comprises:

[0042] In the drawings: 1 - infrared sensor, 2 - MCU controller, 3 - AC contactor, 4 - water pump, 5 - signal indicator, 6 - display screen. DETAILED DESCRIPTION

[0043] The exemplary embodiments will be described in detail herein with reference to the drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application. Instead, they are merely examples of apparatuses and methods consistent with some aspects of the present application as detailed in the appended claims.

[0044] Embodiment One

[0045] Figure 1 is a whole system schematic diagram of a non-contact water level automatic control system according to an exemplary embodiment, and the system comprises:

[0046] Foam stick: arranged in the steaming pot and floating up and down with the change of the water level in the steaming pot;

[0047] Infrared sensor 1: comprising a transmitting end and a receiving end;

[0048] The emitting end is used for continuously emitting infrared rays to irradiate the top of the foam stick at a preset angle; in the initial state of the water level in the steaming pot, part of the infrared rays emitted by the emitting end is reflected by the foam stick to the receiving end of the infrared sensor;

[0049] The receiving end is used for receiving the infrared rays reflected by the foam stick, and the intensity of the infrared rays received by the receiving end changes with the up-and-down floating of the foam stick;

[0050] The infrared sensor 1 converts the intensity of the infrared rays received by the receiving end into an electric signal and sends the electric signal to the MCU controller 2;

[0051] The MCU controller 2 is used for receiving the electric signal sent by the infrared sensor and outputting a high-level signal or a low-level signal to the AC contactor 3 according to the electric signal;

[0052] The AC contactor 3 is used for closing the main contact when the high-level signal is received, so that the water pump 4 is started to start pumping water for the steaming pot; and the AC contactor 3 is also used for opening the main contact when the low-level signal is received, so that the water pump 4 is stopped to stop pumping water for the steaming pot;

[0053] The signal indicator 5 is electrically connected with the MCU controller 2; the signal indicator 5 includes red and green; the signal indicator 5 is green in the normal state (i.e. below the upper limit water level); when the MCU controller 2 sends the high-level signal to the AC contactor 3, the MCU controller 2 synchronously sends a control signal to the signal indicator 5, and the signal indicator 5 is red when the control signal is received; the signal indicator 5 provides an intuitive water level state prompt for an operator;

[0054] The display screen 6 is electrically connected with the MCU controller 2; after the MCU controller 2 receives the electric signal sent by the infrared sensor 1, the MCU controller 2 converts the electric signal into a digital signal and sends the digital signal to the display screen 6; the display screen 6 displays the water level height according to the digital signal, so that an operator can accurately master the water level information.

[0055] It can be understood that the application utilizes the characteristic that the density of the foam stick is far less than that of water, and uses the foam stick as a water level sensing element; when the water level changes, the foam stick moves up and down along the water in the hole of the PVC plastic pipe network under the action of the buoyancy; the displacement change of the foam stick is highly consistent with the water level change; by accurately measuring the position of the foam stick, the water level information can be accurately obtained;

[0056] Before the application is applied, material preparation and installation of positions of various elements are needed, including: collecting old transparent plastic pipes (with an inner diameter of 50 mm and a length of 70 mm, used for manufacturing a water level observation pipe to facilitate an operator to directly observe the water level change), foam sticks (with a diameter of 40 mm and a length of 140 mm, with a density of [X] g / cm 3, infrared sensor 1 (model E3F-DS30C4, detection distance 10cm-30cm, used to detect the position of the foam stick), signal indicator light (DC 24V, red and green, used to display the water level), PVC plastic pipe network (40mm in diameter, 40mm in wall thickness, used to build the water level control pipe network), AC contactor 3 (model CJX2-1810, rated current 18A, used to control the on-off of the water pump circuit), several wires (BVR2.5 square, used to connect various electrical components), MCU controller 2 (a general single-chip microcomputer), and other auxiliary materials (such as screws, nuts, brackets, etc., used to fix and install various parts);

[0057] According to the actual installation space and water level detection range requirements of the steam pot drainage system, PVC plastic pipe network is designed and made. First, the PVC pipe is cut to the required length using a saw, then a hole diameter of 10mm is drilled on the PVC pipe every 20mm, ensuring that water can freely enter and exit the pipe network, and the foam stick can smoothly float up and down in the pipe. At the top and bottom of the PVC pipe network, sealing joints and supports are installed to fix the pipe network near the steam pot drainage outlet, so that it can accurately sense the water level change;

[0058] The infrared sensor 1 is fixed above the PVC plastic pipe network through the matching installation bracket, and its position and angle are adjusted to ensure that the receiving end of the infrared sensor 1 can accurately align the movement track of the foam stick and effectively detect the reflection signal of the foam stick at different water levels;

[0059] The connection line between the infrared sensor 1 and the MCU controller 2 is protected by a transparent plastic tube, which can protect the connection line from water erosion and facilitate observation of the connection line, ensuring normal operation of the line;

[0060] The output pin of the infrared sensor 1 is connected to the signal input pin of the MCU controller 2, and the signal conditioning circuit composed of electronic elements such as resistors and capacitors is used to amplify and filter the electrical signal output by the infrared sensor 1, so as to improve the stability and reliability of the signal. The MCU controller 2 performs logical judgment and processing on the signal. When the water level reaches the set upper and lower limit water level, the MCU controller 2 outputs the corresponding high and low level signals through the output port, triggers the coil action of the AC contactor 3, and realizes the control of the water pump 4. At the same time, the positive pin of the signal indicator lamp 5 is connected to different output ports of the MCU controller 2 respectively, and the negative pin is grounded. The MCU controller 2 controls the on-off of the signal indicator lamp 5 of different colors to display the water level state. For the display screen 6, a special digital display chip is used to convert and drive the water level digital signal output by the MCU controller 2, and the water level distance is displayed on the nixie tube in real time.

[0061] The specific working principle is as follows:

[0062] The infrared sensor 1 is composed of a transmitting end and a receiving end. The transmitting end continuously emits infrared rays. Under normal water level conditions (i.e. initial state of water level), the foam stick is at a certain position, and part of the infrared rays are reflected back to the receiving end. When the water level rises or falls, the position of the foam stick changes, and the intensity of the infrared rays reflected back to the receiving end also changes. The infrared sensor 1 converts the change of the received infrared intensity into an electrical signal output, thereby realizing the detection of the change of the water level. The specific principle is as follows: the foam stick floats up with the water level, which shortens the vertical distance between the foam stick and the infrared sensor 1. The shortened distance makes the reflected light more concentrated, and the light intensity at the receiving end is enhanced. The infrared sensor detects the change of the light intensity, and the output voltage increases accordingly. On the contrary, the water level drops, which makes the foam stick sink, and the vertical distance between the top of the foam stick and the infrared sensor 1 increases. The diffusion of the light leads to the decrease of the light intensity per unit area. The total amount of the scattered light captured by the receiving end of the infrared sensor 1 decreases, and the light intensity decreases. The output voltage decreases accordingly. After receiving the electrical signal, the MCU controller 2 compares the received electrical signal with the electrical signal corresponding to the upper limit water level and the electrical signal corresponding to the lower limit water level. The comparison can be realized by the comparator in the MCU controller 2. When the MCU controller 2 judges that the water level corresponding to the real-time electrical signal rises to the set upper limit water level, a high-level signal is sent to the AC contactor 3, the coil of the AC contactor 3 is energized, the main contact of the AC contactor 3 is closed, and the water pump 4 starts pumping water. When the MCU controller 2 judges that the water level corresponding to the real-time electrical signal drops to the set lower limit water level, a low-level signal is sent to the AC contactor 3, the coil of the AC contactor 3 is de-energized, the main contact of the AC contactor 3 is opened, and the water pump 4 stops pumping water.

[0063] It can be understood that before the system is formally applied, the system needs to be debugged, specifically including: after the system is assembled, comprehensive debugging is carried out, first, water is injected into the steam pot drainage system, the floating condition of the foam stick in the PVC plastic pipe network is observed, it is ensured that the foam stick can move up and down freely and smoothly, and there is no obvious friction with the inner wall of the PVC pipe network, then, using a multimeter and other detection tools, it is checked whether the connection of each electrical element is correct, whether the circuit has short circuit, open circuit and other problems, then, by adjusting the sensitivity adjustment knob of the infrared sensor 1, the infrared sensor 1 can accurately detect the reflection signal of the foam stick at different water level positions, and convert it into stable electrical signal output, at the same time, according to the actual water level control requirement, the appropriate upper and lower limit threshold of water level is set in the MCU controller 2, to ensure that the water pump 4 can be accurately started and stopped at the set upper and lower limit of water level, finally, the signal indicator lamp 5 and the display screen 6 are tested, it is checked whether the display color of the signal indicator lamp 5 is consistent with the water level state, whether the display screen 6 is accurate and clear, in the debugging process, the problems found are adjusted and optimized in time, to ensure that the system can work normally and stably;

[0064] The embodiment also provides a comparative experiment to verify the feasibility and accuracy of the system, specifically including:

[0065] Under different water level heights, a high-precision liquid level meter (with an accuracy of ±0.1 cm) is used as a standard to compare the detection results of the application, in the detection range of 10 cm-50 cm, a test point is set every 5 cm, 10 repeated tests are carried out at each test point, the test results show that the water level detection error of the system is controlled within ±0.5 cm, which meets the accuracy requirement of the steam pot drainage water level control, and the specific test data is shown in the following table:

[0066]

[0067]

[0068] Reliability test:

[0069] The actual working condition of the intermittent vacuum drainage of the steam pot vacuum pump is simulated, the system is tested for a long time, in the process of continuous operation for 1000 hours, the working state of the system is recorded once every 1 hour, including water level detection data, water pump start-stop condition, signal indicator lamp display state and the like, during the test, the system does not have any fault, the water level control is accurate, the water pump starts and stops normally, the signal indicator lamp and the display screen display function normally, which proves that the system has high reliability;

[0070] Anti-interference ability test:

[0071] In the complex electromagnetic environment of the yarn steaming workshop, the anti-interference ability of the test system is tested. By placing high-power motors (power of 55 kW), electric welders (model of ZX7-315) and other interference sources around the system, the running condition of the system is observed. When the interference sources are working, the electromagnetic intensity around the system is detected by using an electromagnetic interference tester, and the maximum can reach 3500 V / m. The test results show that the system can work stably, the water level detection data fluctuation is within ±0.2 cm, the water pump starts and stops normally, and is not obviously affected by external electromagnetic interference, thereby ensuring the accuracy of water level control.

[0072] It can be understood that the same or similar parts in the above embodiments can be mutually referred to, and the contents not described in detail in some embodiments can be referred to the same or similar contents in other embodiments.

[0073] It should be noted that, in the description of the present application, the terms "first", "second" and the like are only used for descriptive purposes and should not be construed as indicating or implying relative importance. In addition, in the description of the present application, unless otherwise specified, the meaning of "a plurality of" is at least two.

[0074] Any process or method descriptions in flow charts or otherwise described herein represent embodiments that can be understood as a sequence of steps of executable instructions for achieving a particular logic function or process, and the scope of the preferred embodiments of the present application includes additional implementations that can not be precisely shown or described in the figures or otherwise described herein, including implementations that can be performed in a different order, in substantially simultaneous fashion, or in reverse order, depending on the functionality involved, as would be understood by persons skilled in the art of the embodiments described herein.

[0075] It should be understood that parts of the present application can be realized by hardware, software, firmware or a combination thereof. In the above embodiments, a plurality of steps or methods can be realized by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if realized by hardware, and as in another embodiment, it can be realized by any one or a combination of the following technologies known in the art: discrete logic circuit with logic gate circuit for implementing logic function on data signal, application specific integrated circuit with suitable combination logic gate circuit, programmable gate array (PGA), field programmable gate array (FPGA) and the like.

[0076] Those skilled in the art of the present technology can understand that all or part of the steps carried out by the above-mentioned embodiment methods can be instructed by a program to complete the relevant hardware, and the program can be stored in a computer readable storage medium. When the program is executed, it includes one of the steps of the method embodiment or a combination thereof.

[0077] In addition, each function unit in each embodiment of the present application can be integrated in one processing module, or each unit can be physically present separately, or two or more units can be integrated in one module. The integrated module can be realized in the form of hardware, or in the form of a software function module. When the integrated module is realized in the form of a software function module and sold or used as an independent product, it can also be stored in a computer readable storage medium.

[0078] The storage medium mentioned above can be a read-only memory, a magnetic disk or an optical disk, etc.

[0079] In the description of the present specification, the description referring to the terms "one embodiment", "some embodiments", "an example", "a specific example" or "some examples" etc. means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily mean the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0080] Although the embodiments of the present application have been shown and described above, it should be understood that the above embodiments are exemplary and should not be construed as limiting the present application, and those skilled in the art can make changes, modifications, replacements and variations to the above embodiments within the scope of the present application.

Claims

1. A non-contact water level automatic control system, characterized in that, The system comprises: foam stick: arranged in the steaming pot, up and down with the change of water level in the steaming pot; infrared sensor: including the transmitting end and the receiving end; the transmitting end for continuous emission of infrared rays to the top of the foam stick at a preset angle; in the initial state of the water level in the steaming pot, part of the infrared rays emitted by the transmitting end is reflected back to the receiving end of the infrared sensor by the foam stick; the receiving end for receiving the infrared rays reflected by the foam stick, the infrared light intensity received by the receiving end changes with the up and down of the foam stick; the infrared sensor converts the infrared light intensity received by the receiving end into an electrical signal and sends it to the MCU controller; MCU controller: for receiving the electrical signal sent by the infrared sensor, and outputting high level signal or low level signal to the AC contactor according to the electrical signal; AC contactor: for receiving high level signal when the main contact is closed, and the water pump starts to pump water to the steaming pot; also for receiving low level signal when the main contact is opened, and the water pump stops pumping water to the steaming pot.

2. The system of claim 1, wherein, Also includes: PVC plastic pipe network; a certain diameter of small holes are opened on the PVC plastic pipe network according to the preset interval, to ensure that water can freely enter and exit the PVC plastic pipe network; the foam stick is arranged in the PVC plastic pipe network, and the foam stick floats up and down in the PVC plastic pipe network according to the change of water level in the steaming pot.

3. The system according to claim 2, wherein the top and bottom of the PVC plastic pipe network are respectively provided with supports and sealing joints; the infrared sensor is fixed above the PVC plastic pipe network through the matching support; the PVC plastic pipe network is fixed at the drain port of the steaming pot.

4. The system according to claim 3, wherein the MCU controller predefines the electrical signal corresponding to the upper limit water level and the electrical signal corresponding to the lower limit water level; when the MCU controller detects that the water level rises to the set upper limit water level according to the electrical signal sent by the infrared sensor, it sends high level signal to the AC contactor; when the MCU controller detects that the water level drops to the set lower limit water level according to the electrical signal sent by the infrared sensor, it sends low level signal to the AC contactor. Also includes:

5. The system of claim 4, wherein, signal indicator light; the signal indicator light is electrically connected with the MCU controller; the signal indicator light includes red and green; the signal indicator light is green in normal state; when the MCU controller sends high level signal to the AC contactor, it synchronously sends control signal to the signal indicator light, and the signal indicator light is red when it receives the control signal. Also includes:

6. The system of claim 5, wherein, display screen; the display screen is electrically connected with the MCU controller; after the MCU controller receives the electrical signal sent by the infrared sensor, it converts the electrical signal into digital signal and sends it to the display screen, and the display screen displays the water level height according to the digital signal. Also includes:

7. The system of claim 6, wherein, transparent plastic tube; the connection line between the infrared sensor and the MCU controller is arranged in the transparent plastic tube. ​

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