IO-link intelligent flow sensor

Abstract

The utility model provides a kind of IO-Link intelligent flow sensor, comprising: shell, probe and circuit part, shell includes upper cover and lower cover, probe is connected between lower cover, circuit part includes flow measurement unit, signal processing unit and IO-Link communication unit, flow measurement unit is located in probe, signal processing unit and IO-Link communication unit are located in shell.Based on IO-Link communication unit, realize two-way communication, both can send signal processing unit processing flow signal, can also receive the adjustment instruction sent by host computer to signal processing unit.Moreover, IO-Link communication unit provides a unified interface, can be higher compatibility to realize plug and play, the calibration of flow signal in signal processing unit, through the setting of temperature compensation unit, reduce the influence of interference, so that the flow precision measured by signal processing unit is more accurate.

Description

Technical Field

[0001] This utility model relates to the instrumentation industry, and in particular to an intelligent flow sensor. Background Technology

[0002] A flow sensor is a device used to measure the flow rate of a fluid (gas or liquid), and it is widely used in industrial automation, environmental monitoring, medical equipment, automotive electronics, and other fields. Types of flow sensors include mechanical flow sensors, differential pressure flow sensors, and thermal flow sensors. Thermal flow sensors calculate flow rate by detecting the heat carried away by the fluid through a heating element and a temperature sensor.

[0003] In the process of developing the existing technology, the inventors discovered that:

[0004] Existing flow sensors typically use analog output to transmit signals. This process is prone to problems such as signal attenuation and poor anti-interference capability during signal transmission. On the other hand, using digital signals with communication protocols such as I2C, SPI, and UART requires custom data formats, has limitations in unidirectional communication distances, and suffers from poor anti-interference capability.

[0005] Based on the above problems, this application provides a flow sensor technology solution with strong anti-interference ability, high compatibility, plug-and-play capability, and remote bidirectional communication capability to solve the problems of poor anti-interference ability, low compatibility, and only unidirectional communication capability in the prior art. Utility Model Content

[0006] In view of the shortcomings of the prior art described above, the purpose of this utility model is to provide a flow sensor technology solution with strong anti-interference ability, high compatibility, plug-and-play capability, and remote bidirectional communication capability to solve the problems of poor anti-interference ability, low compatibility, and only unidirectional communication capability in the prior art.

[0007] To achieve the above and other related objectives, this utility model provides an IO-Link intelligent flow sensor, comprising: a housing, a probe, and a circuit section. The housing includes an upper cover and a lower cover, with the probe connected to the lower cover. The circuit section includes a flow measurement unit, a signal processing unit, and an IO-Link communication unit. The flow measurement unit is located inside the probe, while the signal processing unit and the IO-Link communication unit are located inside the housing. The signal processing unit is electrically connected to both the flow measurement unit and the IO-Link communication unit, respectively, and is used to receive signals transmitted by the flow measurement unit, process them, and output the processed signals to a host computer via the IO-Link communication unit.

[0008] Preferably, it further includes: the host computer outputs adjustment instructions to the IO-Link communication unit, and the IO-Link communication unit transmits the adjustment instructions to the signal processing unit for controlling the flow measurement unit to achieve accurate measurement.

[0009] Preferably, the signal processing unit includes a flow signal receiving module, a flow signal processing module, and a flow signal flow value control module, wherein the flow signal flow value control module is mainly used to calibrate the flow value.

[0010] Preferably, it also includes a temperature compensation unit located inside the probe, connected to the signal processing unit, for performing temperature compensation when calibrating the flow rate value;

[0011] The temperature compensation unit includes at least a temperature acquisition unit and a steam chamber for temperature compensation of the flow detection unit.

[0012] Preferably, the flow measurement unit includes a first thermistor, a second thermistor, and a heat source.

[0013] Preferably, the IO-Link communication unit includes at least a power supply module and an IO-Link interface for signal input or output. The power supply module supplies power to the IO-Link communication unit, the signal processing unit connected to the IO-Link communication unit, and the flow measurement unit and temperature acquisition unit connected to the signal processing unit.

[0014] Preferably, the IO-Link communication unit further includes a fault diagnosis module, which is used to diagnose whether the flow measurement unit and the signal processing unit have malfunctioned.

[0015] Preferably, the housing is further provided with a button unit connected to the signal processing unit, for controlling the signal processing unit via the button unit.

[0016] As described above, the IO-Link intelligent flow sensor provided by this utility model has the following features:

[0017] Beneficial effects:

[0018] Based on the IO-Link communication unit, bidirectional communication is achieved, enabling both the transmission of flow signals processed by the signal processing unit and the reception of adjustment commands from the host computer to the signal processing unit. Furthermore, the IO-Link communication unit provides a unified interface, allowing for highly compatible plug-and-play functionality.

[0019] The calibration of the flow signal in the signal processing unit, through the setting of the temperature compensation unit, reduces the influence of interference, making the flow measured by the signal processing unit more accurate. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of an IO-Link intelligent flow sensor;

[0021] Figure 2 This is a schematic diagram of the circuit part of an intelligent flow sensor;

[0022] Figure 3 A schematic diagram illustrating the process of calibrating the flow value for the flow signal flow value control module;

[0023] Figure 4 This is a schematic diagram of the IO-Link communication unit of an intelligent flow sensor.

[0024] 1. Shell, 11. Top cover, 12. Bottom cover

[0025] 2. Probe,

[0026] 3. Circuit section,

[0027] 31. Flow measurement unit,

[0028] 32. Signal processing unit; 321. Flow signal receiving module; 322. Flow signal processing module; 323. Flow signal flow value control module.

[0029] 33. IO-Link communication unit, 331. Power supply module, 332. Fault diagnosis module.

[0030] 4. Temperature acquisition unit,

[0031] 5. Button unit. Detailed Implementation

[0032] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0033] Please see Figures 1 to 4It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and are not intended to limit the scope of this invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of this invention, should still fall within the scope of the disclosed technical content. Furthermore, the terms "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of this invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of this invention.

[0034] like Figures 1 to 4 As shown, this utility model provides an IO-Link intelligent flow sensor, including: a housing 1, a probe 2, and a circuit section. The housing 1 includes an upper cover 11 and a lower cover 12, with the probe 2 connected to the lower cover 12. The circuit section includes a flow measurement unit 31, a signal processing unit 32, and an IO-Link communication unit 33. The flow measurement unit 31 is located inside the probe 2, and the signal processing unit 32 and the IO-Link communication unit 33 are located inside the housing 1. The signal processing unit 32 is electrically connected to the flow measurement unit 31 and the IO-Link communication unit 33, respectively, and is used to receive the signal transmitted by the flow measurement unit 31, process it through the signal processing unit 32, and output the processed signal to the host computer through the IO-Link communication unit 33.

[0035] Specifically, the housing 1 includes an upper cover 11 and a lower cover 12, which are fixed together by an interference fit. The probe 2 is connected to the lower cover 12 by an interference fit. The probe 2 includes a probe rod and a connecting nut, which serves to fix and lock the probe rod during installation.

[0036] Furthermore, the flow measurement unit 31 includes a first thermistor, a second thermistor, and a heat source.

[0037] The flow measurement unit 31 is located inside the probe 2 and is used for flow measurement. This application employs thermal flow measurement technology. Specifically, a heat source causes a local temperature increase in the medium. The increased temperature is detected by a first thermistor. As long as the medium flows through the heat source, it absorbs heat from the heat source. A second thermistor detects the resulting temperature change, which is used to display the flow rate. To obtain a relatively wide linear range, an accurate measurement result is obtained for the changing medium temperature.

[0038] Furthermore, the signal processing unit 32 includes a flow signal receiving module 321, a flow signal processing module 322, and a flow signal flow value control module 323. The flow signal flow value control module 323 is mainly used to calibrate the flow value.

[0039] The signal processing unit 32 is mainly used to process the signals collected by the flow measurement unit 31. Specifically, the flow signal receiving module 321 is mainly used to receive flow signals. The flow signal processing module 322 is mainly used to filter out irregular and interfering signals, leaving only pure and effective flow signals. The processing of the flow signal processing module 322 includes at least signal filtering and signal amplification. The flow signal flow value control module 323 calibrates the flow value to ensure the accuracy of the flow value. In a preferred embodiment provided in this application, the flow signal flow value control module 323 is equivalent to a microcontroller.

[0040] Furthermore, it also includes a temperature compensation unit located inside the probe 2, which is connected to the signal processing unit 32 and is used to perform temperature compensation when calibrating the flow rate value;

[0041] The temperature compensation unit includes at least a temperature acquisition unit 4 and a steam chamber for temperature compensation of the flow detection unit.

[0042] Specifically, the temperature acquisition unit 4 can accurately sense every slight fluctuation in fluid temperature and convert these fluctuations into identifiable electrical signals, which are then transmitted to the signal processing unit 32. After processing, the signal processing unit 32 further compensates for the flow rate value calibrated by the flow rate control module 323 based on changes in ambient temperature, effectively eliminating the adverse effects of ambient temperature fluctuations on the measurement results, thereby improving measurement accuracy and enabling the entire system to provide accurate and reliable measurement data under different environments. In a preferred embodiment provided in this application, the temperature acquisition unit 4 is preferably a temperature detection element, and the probe 2 contains a steam chamber for temperature compensation of the flow rate detection unit.

[0043] Furthermore, the IO-Link communication unit 33 includes at least a power supply module 331 and an IO-Link interface for signal input or output. The power supply module 331 supplies power to the IO-Link communication unit 33, the signal processing unit 32 connected to the IO-Link communication unit 33, the flow measurement unit 31 connected to the signal processing unit 32, and the temperature acquisition unit 4.

[0044] The power supply module 331 in the IO-Link communication unit 33 is mainly used to supply power to the IO-Link communication unit 33. For example... Figure 3As shown, the power supply module 331 is connected to the IO-Link interface. Of course, reverse polarity protection and undervoltage lockout functions can also be set between the power supply module 331 and the IO-Link interface.

[0045] It should also be noted that a protection circuit can be set between the IO-Link communication unit 33 and the host computer for protection. Under the premise that the IO-Link interface of the IO-Link communication unit 33 and the flow signal flow value control module 323 of the signal processing unit 32 are controlled and monitored, a wake-up detection function can also be set to wake up the hibernating system through a specific signal (such as a button or communication message).

[0046] In addition, the power supply module 331 also supplies power to other modules of the intelligent flow sensor, such as the temperature compensation unit, through the IO-Link communication unit 33.

[0047] Specifically, the IO-Link interface facilitates integration with existing industrial control systems. In this application, the IO-Link communication unit 33 communicates with the host computer via the IO-Link interface, transmitting flow data, status information, and fault diagnosis results. The IO-Link communication unit 33 can efficiently encode and encapsulate the received flow data in real time, transmitting it continuously to the host computer through the stable and reliable IO-Link interface. Upon receiving the flow data, the host computer can utilize advanced software algorithms and data analysis tools for in-depth analysis, thereby achieving comprehensive monitoring and precise control of the fluid flow throughout the production process. The IO-Link communication unit 33 continuously monitors the equipment's operating status and transmits this information to the host computer in real time. Based on the received status information, the host computer can promptly detect potential problems with the equipment and take corresponding preventative measures to avoid production interruptions or quality fluctuations caused by equipment failure.

[0048] Furthermore, the IO-Link communication unit 33 also includes a fault diagnosis module 332, which is used to diagnose whether the flow measurement unit 31 and the signal processing unit 32 have malfunctioned.

[0049] Specifically, the transmission of results from the fault diagnosis module 332 is also an important function of the IO-Link communication unit 33. When the intelligent flow sensor malfunctions, the IO-Link communication module, with its powerful fault diagnosis capabilities, can quickly and thoroughly analyze the fault, accurately determine the type, severity, and potential impact of the fault. It transmits these detailed fault diagnosis results, along with key information such as the time and location of the fault, to the host computer via the IO-Link interface. Upon receiving the fault diagnosis results, the host computer can not only quickly activate emergency plans and take corresponding measures to reduce the impact of the fault on production, but also provide strong data support for subsequent equipment maintenance and repair, helping maintenance personnel to locate and resolve problems more quickly, thereby reducing downtime and improving production efficiency. In a preferred embodiment provided in this application, the fault diagnosis module 332 is used at least to diagnose whether the flow measurement unit 31 and the signal processing unit 32 have malfunctioned.

[0050] Furthermore, the housing 1 is also provided with a button unit 5, which is connected to the signal processing unit 32 and is used to control the signal processing unit 32 through the button unit 5.

[0051] Specifically, the connection between the button unit 5 and the signal processing unit 32 is mainly used to control the signal processing unit 32 through the button, and to achieve accurate measurement by the flow measurement unit 31 through the control of the signal processing unit 32.

[0052] The signal processing unit 32 is electrically connected to the flow measurement unit 31 and the IO-Link communication unit 33 respectively. It is used to receive the signal transmitted by the flow measurement unit 31, process it through the signal processing unit 32, and output the signal processed by the signal processing unit 32 to the host computer through the IO-Link communication unit 33.

[0053] It is understood that the intelligent flow sensor of this application realizes signal transmission through the IO-Link communication unit 33. Compared with the previous analog output and digital signal output, this application can achieve the functions of high compatibility, plug and play and strong anti-interference capability.

[0054] Furthermore, the host computer outputs adjustment commands to the IO-Link communication unit 33, which transmits the adjustment commands to the signal processing unit 32, so that the signal processing unit 32 can control the flow measurement unit 31 to perform accurate measurements.

[0055] Specifically, the intelligent flow sensor of this application achieves bidirectional transmission through the IO-Link communication unit 33. This allows the host computer to issue adjustment commands to adjust the sensor's signal processing unit 32, thereby enabling accurate flow measurement by the flow measurement unit 31. Alternatively, the sensor's signal processing unit 32 can be controlled via the button unit 5, thus achieving accurate flow measurement by the flow measurement unit 31.

[0056] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. An IO-Link intelligent flow sensor, characterized in that, include: The device comprises a housing, a probe, and a circuit. The housing includes an upper cover and a lower cover, with the probe connected to the lower cover. The circuit includes a flow measurement unit, a signal processing unit, and an IO-Link communication unit. The flow measurement unit is located inside the probe, while the signal processing unit and the IO-Link communication unit are located inside the housing. The signal processing unit is electrically connected to both the flow measurement unit and the IO-Link communication unit, respectively, and is used to receive signals transmitted by the flow measurement unit, process them, and then output the processed signals to the host computer via the IO-Link communication unit.

2. The intelligent flow sensor according to claim 1, characterized in that, Also includes: The host computer outputs adjustment commands to the IO-Link communication unit, which then transmits the adjustment commands to the signal processing unit. The signal processing unit controls the flow measurement unit to achieve accurate measurement.

3. The intelligent flow sensor according to claim 2, characterized in that, The signal processing unit includes a flow signal receiving module, a flow signal processing module, and a flow signal flow value control module, wherein the flow signal flow value control module is used to calibrate the flow value.

4. The intelligent flow sensor according to claim 3, characterized in that, It also includes a temperature compensation unit located inside the probe, which is connected to the signal processing unit and is used to perform temperature compensation when calibrating the flow rate value; The temperature compensation unit includes at least a temperature acquisition unit and a steam chamber for temperature compensation of the flow detection unit.

5. The intelligent flow sensor according to claim 1, characterized in that, The flow measurement unit includes a first thermistor, a second thermistor, and a heat source.

6. The intelligent flow sensor according to claim 4, characterized in that, The IO-Link communication unit includes at least a power supply module and an IO-Link interface for signal input or output. The power supply module supplies power to the IO-Link communication unit, the signal processing unit connected to the IO-Link communication unit, and the flow measurement unit and temperature acquisition unit connected to the signal processing unit.

7. The intelligent flow sensor according to claim 6, characterized in that, The IO-Link communication unit also includes a fault diagnosis module, which is used to diagnose whether the flow measurement unit and the signal processing unit have malfunctioned.

8. The intelligent flow sensor according to claim 1, characterized in that, The housing is also provided with a button unit, which is connected to the signal processing unit and is used to control the signal processing unit through the button unit.

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