Full-automatic calibration system for hydrogen sensor
The fully automated calibration system solves the problems of low calibration efficiency, lack of temperature compensation, and insufficient safety of traditional hydrogen sensors, achieving efficient and accurate multi-concentration hydrogen concentration calibration and improved safety, thus meeting the needs of wide-range sensors.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHEJIANG ROCKERSTONE ELECTRONICS TECH CO LTD
- Filing Date
- 2025-05-22
- Publication Date
- 2026-05-15
AI Technical Summary
Traditional hydrogen sensor calibration suffers from problems such as inefficiency due to manual operation, lack of compensation for temperature effects, difficulty in multi-gas calibration, and insufficient safety.
A fully automated calibration system for a hydrogen sensor was designed, including a gas path control unit, a temperature compensation unit, a testing unit, and a tooling mechanism. The system uses a central control module to coordinate a solenoid valve group and a mass flow controller to achieve automatic switching of multiple gas concentrations and precise flow control. The system also incorporates software algorithms to dynamically correct sensor deviations and employs gas-sealed rubber sleeves and leak-proof pipe interfaces to enhance safety.
It achieves efficient and accurate hydrogen concentration calibration, shortens the calibration cycle to 8 minutes, improves the sensor's detection accuracy under extreme temperatures, ensures safety and work efficiency, and meets the needs of multi-concentration calibration.
Smart Images
Figure CN224247740U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of sensor technology, specifically a fully automated calibration system for a hydrogen sensor. Background Technology
[0002] Hydrogen sensors are highly sensitive to hydrogen at room temperature and have excellent selectivity, making them suitable for detecting hydrogen concentration in the environment. Due to safety requirements in production and daily life, fast, sensitive, and accurate hydrogen sensors are essential to prevent the possibility of explosions.
[0003] Traditional hydrogen sensor calibration has the following technical drawbacks:
[0004] 1. Inefficient manual operation: It requires manual switching of gas cylinders and adjustment of flow rate; calibrating a single sensor takes more than 30 minutes.
[0005] 2. Uncompensated for temperature effects: Changes in ambient temperature cause sensor output drift, and existing equipment lacks real-time compensation functionality;
[0006] 3. Difficulty in multi-gas calibration: Most devices only support single-concentration calibration, which cannot meet the requirements of wide-range sensors;
[0007] 4. Insufficient safety: Manual operation is prone to hydrogen leakage, and the tooling has poor sealing.
[0008] To address this, a fully automated calibration system for hydrogen sensors is provided. Utility Model Content
[0009] To address the shortcomings of existing technologies, this application provides a fully automated calibration system for hydrogen sensors, which features improved working efficiency, high-precision temperature compensation, full coverage of multiple concentrations, and enhanced safety.
[0010] To achieve the above objectives, this application provides the following technical solution: a fully automatic calibration system for a hydrogen sensor, comprising a gas path control unit, a temperature compensation unit, a testing unit, and a tooling mechanism. The gas path control unit includes a standard gas cylinder group, a solenoid valve group, and a mass flow controller (MFC). The gas path control unit coordinates the solenoid valve group, the mass flow controller, and the standard gas cylinder group through a central control module (PC software) to achieve automatic switching of multiple gas concentrations and precise flow control.
[0011] The above solution, through the setup of a gas path control unit, temperature compensation unit, testing unit, and tooling mechanism, enables one-button start-up to complete 12-gas cycle tests, shortening the calibration cycle to 8 minutes (traditionally requiring 2 hours). The solenoid valve group is linked with the mass flow controller, reducing gas switching time to <0.5 seconds, thus improving work efficiency. Software algorithms dynamically correct sensor deviations within the -20℃ to 60℃ range, improving accuracy by ±0.5%FS. Independent circuits transmit compensation signals, avoiding signal interference and achieving high-precision temperature compensation. The 12 independent gas paths support 0~100% LEL hydrogen concentration calibration, meeting the needs of various sensors and facilitating automatic saving of test data for each gas, generating complete calibration reports, thus achieving full coverage of multiple concentrations. Gas-sealed rubber sleeves and leak-proof pipe interfaces ensure a hydrogen leakage rate of <1ppm / hour, and the tooling locking mechanism ensures stable sensor installation, preventing test deviation and improving safety.
[0012] Furthermore, the standard gas cylinder group has 12 different concentrations of hydrogen standard gas sources, each gas source is connected through an independent gas pipeline, the solenoid valve group has 12 solenoid valves corresponding to 12 gas paths, controlled by a central control module to achieve automatic gas selection, and the mass flow controller (MFC) is connected to the output of the solenoid valves to adjust the gas flow to the set value and keep it stable.
[0013] With the above solution, 12 independent gas sources combined with an intelligent switching system can complete any concentration switch within 1 second, which is 20 times faster than traditional manual ventilation, and the flow control accuracy is as high as ±0.5%.
[0014] Furthermore, the temperature compensation unit includes an ambient temperature sensor, a signal acquisition circuit, and a software compensation algorithm. The ambient temperature sensor acquires the ambient temperature of the test bench in real time, the signal acquisition circuit transmits the temperature signal to the central control module, and the software compensation algorithm dynamically corrects the sensor output deviation based on the temperature signal.
[0015] Through the above scheme, the unique three-level temperature correction system can eliminate the influence of ambient temperature in real time, enabling the sensor to maintain a detection accuracy of ±1% even in extreme environments ranging from -20℃ to 60℃.
[0016] Furthermore, the testing unit includes a PC control interface, a gas testing module, and a data storage module. The PC control interface is used to set calibration parameters, display test results (OK / NG), and store data. The gas testing module compares the sensor output signal with the standard gas concentration to generate a judgment result. The data storage module records the complete calibration data for each test cycle.
[0017] Through the above solution, the one-click intelligent testing platform automatically completes data comparison and storage, not only displaying OK / NG results in real time, but also generating a complete electronic calibration certificate.
[0018] Furthermore, the tooling mechanism includes a test bench base, a gas-sealing rubber sleeve, and a leak-proof pipeline interface. The test bench base integrates a locking mechanism for fixing the sensor under test. The gas-sealing rubber sleeve surrounds the sensor interface to prevent gas leakage. The leak-proof pipeline interface connects the gas pipeline to the test bench to ensure airtightness.
[0019] The above scheme uses a locking mechanism to clamp the sensor, ensuring that the probe is in contact with the gas-sealed rubber sleeve. Before the gas is introduced, the pressure sensor checks the cavity sealing (>50kPa pressure holding is qualified). After the test, the solenoid valve closes and the locking mechanism automatically resets.
[0020] Furthermore, the solenoid valve assembly is linked with the mass flow controller, and the central control module automatically performs gas purging, switching, and flow regulation operations according to a preset program.
[0021] Through the above scheme, the sequential gas path control achieves millisecond-level response, and the purging-testing-switching process is completed automatically, eliminating human error.
[0022] Furthermore, the correction signal of the temperature compensation unit is transmitted to the sensor through an independent circuit, and the compensation range covers -20℃ to 60℃.
[0023] The above scheme uses a military-grade independent signal channel to transmit compensation data, which improves anti-interference capability by 10 times and ensures that the correction signal is delivered 100% accurately.
[0024] Furthermore, the gas testing module supports cyclic calibration of 12 gas concentrations, and automatically completes data acquisition and judgment under all atmospheres within a single test cycle.
[0025] With the above solution, 12 concentrations can be tested in a fully automated cycle, completing the complex calibration process that traditionally requires multiple disassemblies and reassemblies in a single test, thus improving work efficiency by 8 times.
[0026] Compared with the prior art, the technical solution of this application has the following beneficial effects:
[0027] This fully automated hydrogen sensor calibration system, through the setup of a gas path control unit, temperature compensation unit, testing unit, and tooling mechanism, can complete 12 gas cycle tests with a single button start, shortening the calibration cycle to 8 minutes (compared to 2 hours traditionally). The solenoid valve group is linked with the mass flow controller, reducing gas switching time to <0.5 seconds, thus improving work efficiency. Software algorithms dynamically correct sensor deviations within the -20℃ to 60℃ range, improving accuracy by ±0.5%FS. Independent circuits transmit compensation signals, avoiding signal interference and achieving high-precision temperature compensation. The 12 independent gas paths support hydrogen concentration calibration from 0 to 100% LEL, meeting the needs of various sensors and facilitating automatic saving of test data for each gas, generating complete calibration reports, thus achieving full coverage of multiple concentrations. Gas-sealed rubber sleeves and leak-proof pipe interfaces ensure a hydrogen leakage rate of <1ppm / hour, and the tooling locking mechanism ensures stable sensor installation, preventing test deviation and improving safety. Attached Figure Description
[0028] Figure 1 This is a system flowchart for this application;
[0029] Figure 2 This is a partial schematic diagram of the control unit of this application;
[0030] Figure 3 This is a system diagram of the temperature compensation unit in this application;
[0031] Figure 4 This is a system diagram of the test unit in this application;
[0032] Figure 5 This is a three-dimensional structural diagram of the tooling mechanism in this application.
[0033] In the picture:
[0034] 1. Gas circuit control unit; 101. Standard gas cylinder group; 102. Solenoid valve group; 103. Mass flow controller; 104. Gas circuit pipeline; 2. Temperature compensation unit; 201. Ambient temperature sensor; 202. Signal acquisition circuit; 203. Software compensation algorithm; 3. Test unit; 301. PC control interface; 302. Gas test module; 303. Data storage module; 4. Tooling mechanism; 401. Test bench base; 402. Gas sealing rubber sleeve; 403. Leak-proof pipeline interface; 404. Locking mechanism. Detailed Implementation
[0035] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0036] Please see Figure 1 , Figure 2 and Figure 5 This embodiment describes a fully automated calibration system for a hydrogen sensor, comprising a gas path control unit 1, a temperature compensation unit 2, a testing unit 3, and a tooling mechanism 4. The gas path control unit 1 includes a standard gas cylinder group 101, a solenoid valve group 102, and a mass flow controller 103 (MFC). The gas path control unit 1 coordinates the solenoid valve group 102, the mass flow controller 103, and the standard gas cylinder group 101 through a central control module (PC software) to achieve automatic switching and precise flow control of multiple gas concentrations. By configuring the gas path control unit 1, temperature compensation unit 2, testing unit 3, and tooling mechanism 4, a one-button start-up completes 12-gas cycle testing, shortening the calibration cycle to 8 minutes (traditionally requiring 2 hours). The solenoid valve group 102 and the mass flow controller 103 (MFC)... The flow controller 103 is linked, and the gas switching time is less than 0.5 seconds, thus improving work efficiency. The software algorithm dynamically corrects the sensor deviation within the range of -20℃ to 60℃, improving accuracy by ±0.5%FS. The independent circuit transmits the compensation signal to avoid signal interference, thus achieving high-precision temperature compensation. The 12 independent gas paths support hydrogen concentration calibration from 0 to 100% LEL, meeting the needs of various sensors, and facilitate automatic saving of test data for each gas to generate a complete calibration report, thus achieving full coverage of multiple concentrations. The gas-sealed rubber sleeve 402 and the leak-proof pipe interface 403 ensure a hydrogen leakage rate of less than 1ppm / hour, and the tooling locking mechanism 404 ensures that the sensor is installed firmly, avoiding test deviation and thus improving safety.
[0037] Please see Figure 1 , Figure 2 and Figure 5The standard gas cylinder group 101 has 12 different concentrations of hydrogen standard gas sources, each connected via an independent gas pipeline 104. The solenoid valve group 102 has 12 solenoid valves corresponding to 12 gas paths, controlled by the central control module to achieve automatic gas selection. The mass flow controller 103 (MFC) is connected to the output of the solenoid valves to regulate the gas flow to the set value and maintain stability. The temperature compensation unit 2 includes an ambient temperature sensor 201, a signal acquisition circuit 202, and a software compensation algorithm 203. The ambient temperature sensor 201 collects the ambient temperature of the test bench in real time, the signal acquisition circuit 202 transmits the temperature signal to the central control module, and the software compensation algorithm 203 dynamically corrects the sensor output deviation based on the temperature signal. The test unit 3 includes a PC control interface 301 and a gas test module 302. The system includes a data storage module 303, a PC control interface 301 for setting calibration parameters, displaying test results (OK / NG), and storing data. A gas testing module 302 compares the sensor output signal with the standard gas concentration to generate a judgment result. The data storage module 303 records complete calibration data for each test cycle. With 12 independent gas sources and an intelligent switching system, arbitrary concentration switching can be completed within 1 second, which is 20 times faster than traditional manual gas exchange. The flow control accuracy is as high as ±0.5%. The unique three-level temperature correction system can eliminate the influence of ambient temperature in real time, enabling the sensor to maintain a detection accuracy of ±1% even in extreme environments ranging from -20℃ to 60℃. The one-click intelligent testing platform automatically completes data comparison and storage, not only displaying OK / NG results in real time but also generating a complete electronic calibration certificate.
[0038] Please see Figure 1 , Figure 2 and Figure 5The tooling mechanism 4 includes a test bench base 401, a gas-sealing rubber sleeve 402, and a leak-proof pipeline interface 403. The test bench base 401 integrates a locking mechanism 404 for fixing the sensor under test. The gas-sealing rubber sleeve 402 surrounds the sensor interface to prevent gas leakage. The leak-proof pipeline interface 403 connects the gas pipeline 104 to the test bench to ensure airtightness. The solenoid valve group 102 is linked with the mass flow controller 103, and the central control module automatically performs gas purging, switching, and flow regulation operations according to a preset program. The correction signal of the temperature compensation unit 2 is transmitted to the sensor through an independent circuit, and the compensation range covers -20℃ to 60℃. The gas testing module 302 supports cyclic calibration of 12 gas concentrations. Within a single test cycle, the system automatically completes data acquisition and judgment under all atmospheres. The sensor is clamped by the locking mechanism 404 to ensure contact between the probe and the gas-sealed rubber sleeve 402. Before gas is introduced, the pressure sensor checks the chamber sealing (>50kPa pressure holding is qualified). After the test, the solenoid valve closes and the locking mechanism 404 automatically resets. The sequential gas path control achieves millisecond-level response. The purging-testing-switching process is fully automated, eliminating human error. It adopts a military-grade independent signal channel to transmit compensation data, improving anti-interference capability by 10 times and ensuring 100% accurate delivery of correction signals. It can automatically cycle through 12 concentrations, completing the complex calibration process that traditionally requires multiple disassemblies and reassemblies in a single test, improving work efficiency by 8 times.
[0039] In this embodiment, by setting up a gas path control unit 1, a temperature compensation unit 2, a testing unit 3, and a tooling mechanism 4, 12 kinds of gas cycle tests can be completed with one key start, shortening the calibration cycle to 8 minutes (traditionally 2 hours). The solenoid valve group 102 is linked with the mass flow controller 103, and the gas switching time is <0.5 seconds, thereby improving work efficiency. The software algorithm dynamically corrects the sensor deviation in the range of -20℃ to 60℃, improving the accuracy by ±0.5%FS, and the independent circuit transmits the compensation signal to avoid signal interference, thereby achieving high-precision temperature compensation. The 12 independent gas paths support 0~100%LEL hydrogen concentration calibration, meeting the needs of various sensors, and facilitating the automatic saving of test data for each gas to generate a complete calibration report, thereby achieving full coverage of multiple concentrations. The gas sealing rubber sleeve 402 + leak-proof pipe interface 403 ensures a hydrogen leakage rate of <1ppm / hour, and the tooling locking mechanism 404 ensures that the sensor is installed firmly, avoiding test deviation, thereby improving safety.
[0040] The working principle of the above embodiment is as follows: The PC software sends a command to open the solenoid valve corresponding to the target gas (such as gas line 3), while the other valves are closed. The mass flow controller 103 (MFC) stabilizes the gas flow rate at 200 mL / min (adjustable). Hydrogen gas is first introduced for 5 seconds to purge residual air from the pipeline, ensuring the purity of the test atmosphere. The ambient temperature sensor 201 collects temperature data every 0.5 seconds, which is transmitted to the PC via a signal circuit. The software algorithm calculates the compensation value according to the formula ΔV=k(T-T0) (where k is a coefficient and T0 is the reference temperature). The compensation signal is written to the sensor register through an independent RS-485 circuit. The sensor output signal is compared with the standard gas concentration (such as 2% VOL). H2) Real-time comparison, allowable deviation ±3%. If the deviation is qualified, mark "OK"; otherwise mark "NG" and trigger audible and visual alarm. After completing the current gas test, automatically switch to the next concentration (12 cycles in total). The sensor is clamped by the locking mechanism 404 to ensure that the probe is in close contact with the gas sealing rubber sleeve 402. Before gas is introduced, the pressure sensor detects the sealing of the cavity (>50kPa pressure holding qualified). After the test is completed, the solenoid valve closes and the locking mechanism 404 automatically resets.
[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.
[0042] Although embodiments of this application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A fully automatic calibration system for a hydrogen sensor, comprising a gas path control unit (1), a temperature compensation unit (2), a testing unit (3), and a tooling mechanism (4), characterized in that: The gas circuit control unit (1) includes a standard gas cylinder group (101), a solenoid valve group (102), and a mass flow controller (103). The gas circuit control unit (1) coordinates the solenoid valve group (102), the mass flow controller (103), and the standard gas cylinder group (101) through a central control module to achieve automatic switching of multiple concentration gases and precise flow control.
2. The fully automatic calibration system for a hydrogen sensor according to claim 1, characterized in that: The standard gas cylinder group (101) has 12 different concentrations of hydrogen standard gas sources, each gas source is connected through an independent gas pipeline (104), the solenoid valve group (102) has 12 solenoid valves corresponding to 12 gas paths, controlled by the central control module to realize automatic gas selection, and the mass flow controller (103) is connected to the output end of the solenoid valve to adjust the gas flow to the set value and keep it stable.
3. The fully automatic calibration system for a hydrogen sensor according to claim 1, characterized in that: The temperature compensation unit (2) includes an ambient temperature sensor (201), a signal acquisition circuit (202), and a software compensation algorithm (203). The ambient temperature sensor (201) collects the ambient temperature of the test bench in real time. The signal acquisition circuit (202) transmits the temperature signal to the central control module. The software compensation algorithm (203) dynamically corrects the sensor output deviation based on the temperature signal.
4. The fully automatic calibration system for a hydrogen sensor according to claim 1, characterized in that: The test unit (3) includes a PC control interface (301), a gas test module (302), and a data storage module (303). The PC control interface (301) is used to set calibration parameters, display test results, and store data. The gas test module (302) compares the sensor output signal with the standard gas concentration to generate a judgment result. The data storage module (303) records the complete calibration data for each test cycle.
5. The fully automatic calibration system for a hydrogen sensor according to claim 1, characterized in that: The tooling mechanism (4) includes a test bench base (401), a gas-sealing rubber sleeve (402), and a leak-proof pipe interface (403). The test bench base (401) integrates a locking mechanism (404) for fixing the sensor under test. The gas-sealing rubber sleeve (402) surrounds the sensor interface to prevent gas leakage. The leak-proof pipe interface (403) connects the gas pipeline (104) to the test bench to ensure airtightness.
6. The fully automatic calibration system for a hydrogen sensor according to claim 2, characterized in that: The solenoid valve assembly (102) is linked with the mass flow controller (103), and the central control module automatically performs gas purging, switching and flow regulation operations according to a preset program.
7. The fully automatic calibration system for a hydrogen sensor according to claim 3, characterized in that: The correction signal of the temperature compensation unit (2) is transmitted to the sensor through an independent circuit, and the compensation range covers -20℃ to 60℃.
8. The fully automatic calibration system for a hydrogen sensor according to claim 4, characterized in that: The gas testing module (302) supports cyclic calibration of 12 gas concentrations and automatically completes data acquisition and judgment under all atmospheres within a single test cycle.