High-corrosion ultrasonic distance measuring sensor

Abstract

The utility model discloses a high-corrosion ultrasonic distance measuring sensor, relates to the technical field of sensors, and aims to solve the problems that the conventional ultrasonic distance measuring sensor is extremely easy to corrode in a corrosive environment with relatively high acid-base concentration, so that the performance is reduced and even fails, accurate distance measuring data cannot be stably and continuously output, and the measurement accuracy is low. The sensor comprises a sensor shell and a sealing end cover detachably installed at the tail end of the sensor shell, the sensor shell and the sealing end cover are both made of 316l stainless steel materials, and Teflon coatings are arranged on the surfaces of the sensor shell and the sealing end cover. According to the utility model, the corrosion resistance of the sensor in a high-corrosion environment is greatly enhanced, the defects of a conventional sensor in an acid-base environment are effectively overcome, accurate distance measurement data can be continuously and stably output in the acid-base environment, and the requirements of industrial production and chemical experiments on accurate distance measurement in the high-corrosion environment are met.

Description

Technical Field

[0001] This utility model relates to the field of sensor technology, and more specifically, to a highly corrosive ultrasonic ranging sensor. Background Technology

[0002] In many scenarios such as industrial production and chemical experiments, it is often necessary to accurately measure the liquid level in containers and the distance between objects.

[0003] However, conventional ultrasonic ranging sensors are mostly adapted to ordinary environments. In corrosive environments with high acid and alkali concentrations, the electronic components of the sensors are easily corroded, leading to performance degradation or even failure. This results in an inability to stably and continuously output accurate ranging data, greatly limiting their application range. Therefore, we propose a highly corrosive ultrasonic ranging sensor. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology, adapt to practical needs, and provide a highly corrosive ultrasonic ranging sensor to solve the technical problem that current ultrasonic ranging sensors are easily corroded in corrosive environments with high acid and alkali concentrations, leading to performance degradation or even failure, and are unable to output accurate ranging data stably and continuously, which greatly limits their application scope.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a highly corrosive ultrasonic ranging sensor, including a sensor housing and a detachable sealing end cap installed at the tail end of the sensor housing;

[0006] The sensor housing and the sealing end cap are both made of 316L stainless steel, and the surfaces of the sensor housing and the sealing end cap are coated with Teflon. The sensor housing and the sealing end cap form a sealed chamber, and a measuring unit is arranged in the sealed chamber.

[0007] The measurement unit includes an ultrasonic transmitting module for emitting ultrasonic waves, an ultrasonic receiving module for receiving echoes, a microprocessor for integrated control, and a power supply module for powering the sensor.

[0008] Both the ultrasonic transmitting module and the ultrasonic receiving module are electrically connected to the microprocessor. The ultrasonic receiving module is electrically connected to an environmental compensation module for adjusting the sensor's operating parameters according to environmental indicators and a communication module for wireless communication. The environmental compensation module and the communication module are electrically connected to a storage module for information storage.

[0009] The high-corrosion ultrasonic ranging sensor effectively overcomes the defects of conventional sensors in an acid-base environment.

[0010] Preferably, the power module is electrically connected with the ultrasonic wave transmitting module, the ultrasonic wave receiving module, the microprocessor, the environment compensation module, the communication module and the storage module, and the power module comprises a sealed lithium battery pack, a power management circuit for ensuring stable output of electric energy and a temporary power backup power system for providing temporary power for the sensor.

[0011] Preferably, the sealed lithium battery pack and the backup power system are both electrically connected with the power management circuit, so that switching between the sealed lithium battery pack and the backup power system in an emergency state is realized.

[0012] Preferably, the communication module comprises an optical fiber communication interface for transmitting data to an external device through an optical fiber, a communication protocol converter capable of automatically switching a communication mode according to a communication protocol of the external device and a data encryption unit for performing encryption processing on the transmission data, and the data encryption unit is electrically connected with the communication protocol converter and the optical fiber communication interface.

[0013] Preferably, the environment compensation module comprises a temperature and humidity sensor and a pressure sensor for monitoring temperature and humidity and pressure information of the environment in real time, and the temperature and humidity sensor and the pressure sensor are both electrically connected with the microprocessor.

[0014] Preferably, the ultrasonic wave transmitting module comprises a plurality of small piezoelectric ceramic sheet arrays for realizing focusing and directional transmission of ultrasonic wave beams, the small piezoelectric ceramic sheet arrays are composed of a plurality of special piezoelectric ceramic sheets, and the surfaces of the special piezoelectric ceramic sheets are covered with a corrosion-resistant ceramic coating.

[0015] Preferably, the ultrasonic wave receiving module comprises a receiving probe, a signal amplification circuit and a self-adaptive filtering circuit for filtering noise interference in an acid-base environment, the surface of the receiving probe is covered with a corrosion-resistant piezoelectric coating, and the receiving probe is connected with the signal amplification circuit.

[0016] Preferably, the surface of the receiving probe is further provided with an electromagnetic shielding layer for shielding electromagnetic interference in an acid-base environment, and the electromagnetic shielding layer is composed of a plurality of layers of metal foils and insulating materials which are alternately compounded.

[0017] Compared with the prior art, the ultrasonic ranging sensor has the advantages that:

[0018] 1. The high-corrosion ultrasonic ranging sensor effectively overcomes the drawbacks of conventional sensors in an acid-base environment. The sensor shell and the sealing end cover are made of 316L stainless steel material and coated with a Teflon coating, combined with targeted corrosion-resistant design of each module, greatly enhancing the corrosion resistance of the sensor in a high-corrosion environment, stable operation of each module, ensuring that accurate ranging data can be continuously and stably output in an acid-base environment, meeting the demand for accurate ranging in a high-corrosion environment in industrial production and chemical experiments.

[0019] 2. The utility model further improves the stability and accuracy of the sensor in measuring in a high-corrosion environment on the basis of solving the main problem, the environment compensation module monitors the environmental temperature and humidity and pressure information in real time through the temperature and humidity sensor and the pressure sensor, and the microprocessor compensates and calibrates the measurement result accordingly, ensuring that the measurement is not affected by environmental changes, the optical fiber communication interface, the communication protocol converter and the data encryption unit of the communication module ensure the stability, reliability and safety of data transmission. At the same time, the small piezoelectric ceramic sheet array of the ultrasonic transmitting module realizes beam focusing and directional transmission, and the adaptive filter circuit of the receiving module effectively filters noise interference, which comprehensively improves the measurement performance of the sensor in a complex acid-base environment and provides more high-quality, stable and accurate measurement data for various application scenarios. BRIEF DESCRIPTION OF DRAWINGS

[0020] Fig. 1 It is a schematic diagram of the overall structure of the utility model;

[0021] Fig. 2 It is a schematic diagram of the internal structure of the utility model in a split state;

[0022] Fig. 3 It is a schematic diagram of the structure of the measurement unit in the utility model.

[0023] Explanation of reference numerals in the drawing:

[0024] 1. Sensor shell; 2. Sealing end cover; 3. Measurement unit; 301. Ultrasonic transmitting module; 302. Ultrasonic receiving module; 303. Microprocessor; 304. Environment compensation module; 305. Communication module; 306. Storage module; 307. Power module. DETAILED DESCRIPTION

[0025] As shown in Figs. 1 to 3 The utility model relates to a kind of high-corrosion ultrasonic ranging sensor, including sensor shell (1) and the sealing end cover (2) of detachable installation in the tail end of sensor shell (1);

[0026] The sensor shell (1) and the sealing end cover (2) are both made of 316l stainless steel, and the surfaces of the sensor shell (1) and the sealing end cover (2) are arranged with Teflon coating, and the sensor shell (1) and the sealing end cover (2) form a sealed chamber, and the sealed chamber is arranged with a measuring unit (3);

[0027] The measuring unit (3) comprises an ultrasonic wave emitting module (301) for emitting ultrasonic waves, an ultrasonic wave receiving module (302) for receiving echoes, a microprocessor (303) for integrated control, and a power module (307) for powering the sensor;

[0028] The ultrasonic wave emitting module (301) and the ultrasonic wave receiving module (302) are electrically connected with the microprocessor (303), and the ultrasonic wave receiving module (302) is electrically connected with an environmental compensation module (304) for adjusting sensor working parameters according to environmental indicators and a communication module (305) for realizing wireless communication, and the environmental compensation module (304) and the communication module (305) are commonly electrically connected with a storage module (306) for storing information.

[0029] The high-corrosion ultrasonic ranging sensor effectively overcomes the disadvantages of conventional sensors in acid-base environments. The sensor shell and the sealing end cover are made of 316l stainless steel and coated with Teflon, and the targeted corrosion-resistant design of each module greatly enhances the corrosion resistance of the sensor in high-corrosion environments, and the stable operation of each module ensures that accurate ranging data can be continuously and stably output in acid-base environments, meeting the demand for accurate ranging in high-corrosion environments in industrial production and chemical experiments.

[0030] In the embodiment of the utility model, the power module (307) is electrically connected with the ultrasonic wave emitting module (301), the ultrasonic wave receiving module (302), the microprocessor (303), the environmental compensation module (304), the communication module (305) and the storage module (306), and the power module (307) comprises a sealed lithium battery pack, a power management circuit for ensuring stable output of electric energy and a temporary power backup power system for providing power for the sensor.

[0031] In the embodiment of the utility model, the sealed lithium battery pack and the backup power system are electrically connected with the power management circuit, so as to realize the switching of the sealed lithium battery pack and the backup power system in an emergency state.

[0032] In the embodiment of the utility model, the communication module (305) includes the optical fiber communication interface for transmitting data to external equipment through optical fiber, the communication protocol converter that can switch communication mode according to the communication protocol of external equipment and the data encryption unit for carrying out encryption processing to transmission data, the data encryption unit is connected with the communication protocol converter and the optical fiber communication interface electrically.

[0033] In the embodiment of the utility model, the environmental compensation module (304) includes the temperature and humidity sensor and pressure sensor for monitoring the temperature and humidity and pressure information of environment in real time, and the temperature and humidity sensor and pressure sensor are electrically connected with the microprocessor (303).

[0034] In the embodiment of the utility model, the ultrasonic wave transmitting module (301) includes a plurality of small piezoelectric ceramic sheet arrays for realizing the focusing and directional emission of ultrasonic wave beam, the small piezoelectric ceramic sheet array is composed of several special piezoelectric ceramic sheets, and the surface of the special piezoelectric ceramic sheet is covered with a corrosion-resistant ceramic coating.

[0035] In the embodiment of the utility model, the ultrasonic wave receiving module (302) includes a receiving probe, a signal amplification circuit and an adaptive filtering circuit for filtering noise interference in acid and alkali environment, the surface of the receiving probe is covered with a corrosion-resistant piezoelectric coating, and the receiving probe is connected with the signal amplification circuit.

[0036] In the embodiment of the utility model, the surface of the receiving probe is further covered with an electromagnetic shielding layer for shielding electromagnetic interference in acid and alkali environment, and the electromagnetic shielding layer is composed of multiple layers of metal foil and insulating material alternately compounded.

[0037] The utility model further improves the stability and accuracy of the sensor in the high corrosion environment on the basis of solving the main problem, the environmental compensation module monitors the temperature and humidity and pressure information of environment in real time through the temperature and humidity sensor and pressure sensor, and the microprocessor compensates and calibrates the measurement result accurately accordingly, so that the measurement is not affected by environmental changes, and the optical fiber communication interface, communication protocol converter and data encryption unit of the communication module ensure the stability, reliability and safety of data transmission. Meanwhile, the small piezoelectric ceramic sheet array of the ultrasonic wave transmitting module realizes beam focusing and directional emission, and the adaptive filtering circuit of the receiving module effectively filters noise interference, which comprehensively improves the measurement performance of the sensor in the complex acid and alkali environment and provides more high-quality, stable and accurate measurement data for various application scenarios.

[0038] Working principle: the embodiment provides a kind of high corrosion ultrasonic ranging sensor, when sensor starts, power module (307) is powered for the whole system, wherein sealed lithium battery pack provides stable power in normal state, power management circuit guarantees stable output of electric energy.Under the control of microprocessor (303), ultrasonic wave emission module (301) starts work.The emission end is composed of multiple small piezoelectric ceramic sheet arrays, these special piezoelectric ceramic sheet surfaces are covered with corrosion-resistant ceramic coating, which can convert electrical signals into ultrasonic signals.By controlling the excitation sequence and time of small piezoelectric ceramic sheet array, the focusing and directional emission of ultrasonic wave beam are realized, and ultrasonic wave is emitted to target object with specific frequency and intensity, to ensure that the signal can be effectively transmitted to the target position, and not be affected too much in high corrosion acid-base environment.

[0039] The emitted ultrasonic wave propagates in the medium, and reflects back to form echo after encountering the target object.The ultrasonic wave receiving module (302) is responsible for capturing these echo signals.The receiving probe surface is covered with corrosion-resistant piezoelectric coating, and is covered with an electromagnetic shielding layer composed of multiple layers of metal foil and insulating material alternately compounded, which not only can effectively resist the corrosion of acid-base environment, but also can shield external electromagnetic interference.After the echo signal is received by the receiving probe, it is transmitted to the signal amplification circuit for amplification processing, and then passes through the adaptive filter circuit, which automatically adjusts the filter parameters according to the frequency spectrum characteristics of environmental noise, effectively filters out various noise interference generated in acid-base environment, so that the received echo signal is more clear and accurate.

[0040] The processed echo signal is transmitted to microprocessor (303).At the same time, the temperature and humidity sensor and pressure sensor in the environmental compensation module (304) monitor the temperature and humidity and pressure information of the environment in real time, and these data are also transmitted to microprocessor (303).Microprocessor (303) accurately calculates the distance between sensor and target object according to the received echo signal time difference and environmental temperature and humidity and pressure data.Because environmental factors will affect the propagation speed of ultrasonic wave, microprocessor (303) uses environmental compensation algorithm to compensate and calibrate the measurement results according to environmental parameters, to ensure that the accuracy of measurement results is not affected by environmental changes.

[0041] The calculated distance data and related environmental parameters and other information are stored in storage module (306) for subsequent query and analysis.On the other hand, communication module (305) transmits these data.The optical fiber communication interface in communication module (305) transmits data to external equipment through optical fiber, and communication protocol converter can automatically switch communication mode according to the communication protocol of external equipment, to ensure that data can be smoothly transmitted to different types of equipment.At the same time, data encryption unit encrypts the transmitted data to ensure the security and confidentiality of data in transmission process.

[0042] During the whole working process, the power module (307) continuously supplies power to each module. When the sealed lithium battery pack is in an emergency state such as insufficient power or failure, the power management circuit can realize seamless switching between the sealed lithium battery pack and the standby power supply system, ensure that the sensor will not stop working due to power problems, and ensure the integrity of the data and the stability of the system.

[0043] The embodiments of the utility model discloses the preferable embodiment, but is not limited to this, the ordinary skill of the art, the spirit of the utility model is appreciated to the above-mentioned embodiment, and different extension and change are made, but as long as not departing from the spirit of the utility model, all are within the protection scope of the utility model.

Claims

1. A highly corrosive ultrasonic ranging sensor, characterized in that, Includes a sensor housing (1) and a detachable sealing end cap (2) mounted on the tail end of the sensor housing (1); The sensor housing (1) and the sealing end cap (2) are both made of 316L stainless steel, and the surfaces of the sensor housing (1) and the sealing end cap (2) are coated with Teflon. The sensor housing (1) and the sealing end cap (2) form a sealed chamber, and a measuring unit (3) is arranged in the sealed chamber. The measurement unit (3) includes an ultrasonic transmitting module (301) for emitting ultrasonic waves, an ultrasonic receiving module (302) for receiving echoes, a microprocessor (303) for integrated control, and a power supply module (307) for powering the sensor. Both the ultrasonic transmitting module (301) and the ultrasonic receiving module (302) are electrically connected to the microprocessor (303). The ultrasonic receiving module (302) is electrically connected to an environmental compensation module (304) for adjusting the sensor's operating parameters according to environmental indicators and a communication module (305) for wireless communication. The environmental compensation module (304) and the communication module (305) are electrically connected to a storage module (306) for storing information.

2. The highly corrosive ultrasonic ranging sensor according to claim 1, characterized in that, The power module (307) is electrically connected to the ultrasonic transmitting module (301), ultrasonic receiving module (302), microprocessor (303), environmental compensation module (304), communication module (305) and storage module (306), and the power module (307) includes a sealed lithium battery pack, a power management circuit to ensure stable power output, and a backup power system to provide temporary power to the sensor.

3. The highly corrosive ultrasonic ranging sensor according to claim 2, characterized in that, Both the sealed lithium battery pack and the backup power system are electrically connected to the power management circuit.

4. The highly corrosive ultrasonic ranging sensor according to claim 1, characterized in that, The communication module (305) includes an optical fiber communication interface for transmitting data to an external device via optical fiber, a communication protocol converter that can automatically switch communication modes according to the communication protocol of the external device, and a data encryption unit for encrypting the transmitted data. The data encryption unit is electrically connected to the communication protocol converter and the optical fiber communication interface.

5. A highly corrosive ultrasonic ranging sensor according to claim 1, characterized in that, The environmental compensation module (304) includes a temperature and humidity sensor and a pressure sensor for real-time monitoring of environmental temperature, humidity and pressure information. Both the temperature and humidity sensor and the pressure sensor are electrically connected to the microprocessor (303).

6. A highly corrosive ultrasonic ranging sensor according to claim 1, characterized in that, The ultrasonic transmitting module (301) includes multiple small piezoelectric ceramic sheet arrays for focusing and directional transmission of ultrasonic beams. The small piezoelectric ceramic sheet arrays are composed of several specially made piezoelectric ceramic sheets, and the surface of the specially made piezoelectric ceramic sheets is covered with a corrosion-resistant ceramic coating.

7. A highly corrosive ultrasonic ranging sensor according to claim 1, characterized in that, The ultrasonic receiving module (302) includes a receiving probe, a signal amplification circuit, and an adaptive filtering circuit for filtering noise interference in acidic and alkaline environments. The surface of the receiving probe is covered with a corrosion-resistant piezoelectric coating, and the receiving probe is connected to the signal amplification circuit.

8. A highly corrosive ultrasonic ranging sensor according to claim 7, characterized in that, The surface of the receiving probe is also covered with an electromagnetic shielding layer for shielding electromagnetic interference in acidic and alkaline environments. The electromagnetic shielding layer is composed of multiple layers of metal foil and insulating material alternately composited.

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