Intelligent fluid monitoring device for aluminum tubes

Abstract

The utility model relates to an intelligent fluid monitoring device of aluminium pipe, it includes: pressure sensing array contains at least three with equiangular interval embedding annular groove of pressure sensing unit that opens in the thickness direction of aluminium pipe body outer wall, and the induction surface of each pressure sensing unit is conformal contact with the inner wall of groove, temperature compensation subassembly contains along the aluminium pipe body outer wall axial interval distribution multiple temperature sensing unit, signal processing subassembly is connected each pressure sensing unit and each temperature sensing unit through flexible conductive medium respectively, self -power supply subassembly contains the vibration energy collection unit of sticking aluminium pipe body, and the rectifier unit that is connected with vibration energy collection unit output end and is connected with temperature compensation subassembly and signal processing subassembly respectively with energy storage unit. The above structure improvement cooperation, under the prerequisite of not needing external power supply and complex calibration, synchronous achieves high accuracy monitoring, strong environmental adaptation and long -term endurance, provides reliable and low -cost monitoring scheme.

Description

Technical Field

[0001] This utility model relates to the field of industrial fluid transportation technology, and in particular to an intelligent fluid monitoring device for aluminum tubes. Background Technology

[0002] In industrial fluid transport systems, aluminum pipes are widely used due to their lightweight and corrosion-resistant properties. Real-time monitoring of fluid pressure changes within the pipes is crucial for ensuring the safe operation of the system. Existing aluminum pipe pressure monitoring technologies mainly employ the following two approaches:

[0003] The first type is the implantable pressure sensor, which requires embedding the sensor inside the pipeline. Therefore, it alters the flow state of the fluid in the original pipeline, introducing more influencing factors. More importantly, the sensor's sealing interface is prone to leakage due to long-term fluid erosion, resulting in drawbacks such as short maintenance cycles and high installation complexity.

[0004] External pressure sensors are fixed to the outer wall of an aluminum tube using clamps or welding, indirectly measuring fluid pressure through contact-based mechanical transmission. Because the nonlinear relationship between the deformation of the aluminum tube's outer wall and the internal fluid pressure is significant, this method requires complex calibration algorithms, and after long-term use, mechanical fatigue can easily lead to sensor displacement or poor contact, making it difficult to maintain monitoring accuracy.

[0005] Furthermore, in real industrial environments, factors such as mechanical vibration, thermal cycling, or the presence of uneven external heat sources can cause irreversible drift in the contact impedance between the sensor and the pipe wall, leading to a significant decrease in the signal-to-noise ratio of the measurement signal over time. In terms of power supply, external power supply deployment is difficult, while the built-in battery has limited endurance, making it difficult to support the operation of high-power modules.

[0006] Therefore, existing aluminum tube fluid pressure monitoring technology faces technical bottlenecks in terms of maintaining measurement accuracy, suppressing environmental interference, and system endurance, which restricts its reliable application in actual industrial scenarios. Utility Model Content

[0007] (a) Technical problems to be solved

[0008] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides an intelligent fluid monitoring device for aluminum tubes, which solves the technical problems of insufficient measurement accuracy, lack of environmental interference suppression, and difficulty in maintaining the system's endurance for a long time in the existing aluminum tube fluid pressure monitoring technology.

[0009] (II) Technical Solution

[0010] To achieve the above objectives, the main technical solutions adopted by this utility model include:

[0011] In a first aspect, embodiments of the present invention provide an intelligent fluid monitoring device for aluminum tubes, comprising:

[0012] The pressure sensing array includes at least three pressure sensing units that are embedded at equal angular intervals in annular channels opened in the thickness direction of the outer wall of the aluminum tube body, and the sensing surface of each pressure sensing unit is conformally in contact with the inner wall of the channel.

[0013] The temperature compensation component includes multiple temperature sensing units that are axially spaced along the outer wall of the aluminum tube body.

[0014] The signal processing component is connected to each pressure sensing unit and each temperature sensing unit via a parallel bus architecture through a flexible conductive medium.

[0015] The self-powered component includes a vibration energy harvesting unit that fits into the aluminum tube body, a rectifier unit connected to the output of the vibration energy harvesting unit, and an energy storage unit that is connected to the temperature compensation component and the signal processing component respectively.

[0016] Optionally, the axial cross-section of the channel is U-shaped, and the inner wall of the channel is provided with an anodized insulating layer.

[0017] Optionally, the temperature sensing unit is disposed in the axial projection gap area of ​​the adjacent pressure sensing unit to form an axially staggered layout, and the axial spacing of each temperature sensing unit is 1.2-1.5 times the width of the pressure sensing unit.

[0018] Optionally, the temperature sensing unit comprises, from the outer wall of the aluminum tube outwards, the following components:

[0019] The primary temperature sensing layer is composed of a platinum metal film continuously wound in a spiral shape around the outer wall surface of the aluminum tube.

[0020] The insulating layer is an alumina dielectric layer covering the primary temperature sensing layer;

[0021] The secondary backup layer contains multiple independent linear platinum film units arranged along the axial direction of the aluminum tube. Each linear platinum film unit is connected to the signal processing component through a tapered conductive channel passing through the insulating isolation layer. The entrance end of the tapered conductive channel is located on the upper surface of the secondary backup layer, and the exit end is located in the spiral gap area on the surface of the primary temperature sensing layer.

[0022] Optionally, the signal processing component includes:

[0023] A programmable gain instrumentation amplifier, the input of which is connected to the output electrodes of each pressure sensing unit via gold wire bonding;

[0024] A Σ-Δ analog-to-digital converter, integrated with a programmable gain instrumentation amplifier, is mounted on the same ceramic package substrate;

[0025] The shielded housing encloses the programmable gain instrumentation amplifier and the Σ-Δ analog-to-digital converter, with the housing grounding terminal welded to the inner wall of the aluminum tube body.

[0026] Optionally, the flexible conductive medium is a parallel bus composed of multiple strands of twisted copper wires. Each strand of twisted copper wire is independently connected to the output end of the corresponding pressure sensing unit and temperature sensing unit, and is attached and fixed to the outer wall of the aluminum tube body through a silicone layer, and extends along the axial direction of the aluminum tube in a serpentine manner.

[0027] Optionally, the vibration energy harvesting unit is composed of multiple piezoelectric ceramic plates, each piezoelectric ceramic plate is arranged in a spiral along the axial direction of the aluminum tube body and fixed to the outer wall surface of the aluminum tube in the vibration antinode region;

[0028] The rectifier unit is a bridge rectifier circuit, encapsulated in a metal shielded housing with heat sink fins, and the shielded housing is fixed to the outer wall of the aluminum tube body near the vibration energy acquisition unit by bolts.

[0029] The energy storage unit includes at least two supercapacitors connected in parallel and fixed to the non-vibration area of ​​the outer wall of the aluminum tube by a snap-fit ​​bracket. An elastic buffer pad is provided between the snap-fit ​​bracket and the outer wall of the aluminum tube.

[0030] Optionally, it also includes: a LoRa wireless transmission component, which is connected to the signal processing component via an SPI interface, and whose power input is connected to the output of the energy storage unit.

[0031] Optionally, the output of the supercapacitor is connected to a low-dropout linear regulator, which supplies power to the temperature compensation component, the signal processing component, and the LoRa wireless transmission component through independent power supply lines.

[0032] Optionally, the antenna of the LoRa wireless transmission component is a flexible PCB antenna, which is attached to the circumferential non-vibration area of ​​the outer wall of the aluminum tube and fixed by a high-temperature resistant adhesive layer. The antenna feed point is connected to the output terminal of the low-dropout linear regulator through a shielded cable.

[0033] (III) Beneficial Effects

[0034] The beneficial effects of this utility model are:

[0035] First, the structural design of the pressure sensing unit embedded in the channel directly captures the deformation of the pipe wall through the conformal contact interface, eliminating the measurement error caused by poor contact of the external sensor. Combined with the multi-angle symmetrical layout, it realizes the full circumferential sensing of pressure distribution, which significantly improves the measurement accuracy and stability.

[0036] Secondly, the temperature compensation component integrated on the outer wall of the aluminum tube works in conjunction with the sensing unit to dynamically compensate for the temperature drift effect caused by uneven heat conduction along the circumference of the pipe, overcoming the limitations of traditional single-point compensation and ensuring the consistency of measurement data.

[0037] Meanwhile, the flexible conductive medium connects the signal processing components, ensuring lossless signal transmission while absorbing mechanical vibration stress through dielectric deformation, effectively avoiding fatigue damage to the connecting components and enhancing vibration resistance and long-term reliability.

[0038] Finally, the designed self-powered component achieves a continuous and stable energy supply through efficient energy harvesting and intelligent energy storage and distribution, solving the problems of difficult wiring and inconvenient battery replacement under complex working conditions, and significantly extending the maintenance-free operation cycle of the device.

[0039] The aforementioned structural improvements work together to simultaneously achieve high-precision monitoring, strong environmental adaptability, and long-lasting operation without the need for external power supply or complex calibration, providing a reliable and low-cost solution for intelligent monitoring of aluminum tube fluid systems. Attached Figure Description

[0040] Figure 1 A schematic diagram of the device structure provided for an embodiment of this utility model;

[0041] Figure 2 A schematic diagram of the structural composition of the temperature sensing unit provided in an embodiment of this utility model.

[0042] [Explanation of Labels in the Attached Image]

[0043] 1: Aluminum tube body;

[0044] 2: Pressure sensing unit;

[0045] 3: Temperature sensing unit. Detailed Implementation

[0046] To better explain and facilitate understanding of this utility model, the present utility model will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0047] like Figure 1As shown in the figure, an intelligent fluid monitoring device for an aluminum tube according to an embodiment of the present invention includes: a pressure sensing array comprising at least three pressure sensing units 2 embedded at equal angular intervals in annular channels opened in the thickness direction of the outer wall of the aluminum tube body 1, wherein the sensing surface of each pressure sensing unit 2 is conformally in contact with the inner wall of the channel; a temperature compensation component comprising a plurality of temperature sensing units 3 spaced apart along the axial direction of the outer wall of the aluminum tube body 1; a signal processing component connecting each pressure sensing unit 2 and temperature sensing unit 3 respectively via a parallel bus architecture through a flexible conductive medium; and a self-powered component comprising a vibration energy acquisition unit attached to the aluminum tube body 1, a rectifier unit connected to the output end of the vibration energy acquisition unit, and an energy storage unit connected to the temperature compensation component and the signal processing component respectively.

[0048] First, the structural design of the pressure sensing unit 2 embedded in the channel directly captures the deformation of the pipe wall through the conformal contact interface, eliminating the measurement error caused by poor contact of the external sensor. Combined with the multi-angle symmetrical layout, it realizes the full circumferential sensing of pressure distribution, which significantly improves the measurement accuracy and stability.

[0049] Secondly, the temperature compensation component integrated on the outer wall of the aluminum tube works in conjunction with the sensing unit to dynamically compensate for the temperature drift effect caused by uneven heat conduction along the circumference of the pipe, overcoming the limitations of traditional single-point compensation and ensuring the consistency of measurement data.

[0050] Meanwhile, the flexible conductive medium connects the signal processing components, ensuring lossless signal transmission while absorbing mechanical vibration stress through dielectric deformation, effectively avoiding fatigue damage to the connecting components and enhancing vibration resistance and long-term reliability.

[0051] Finally, the designed self-powered component achieves a continuous and stable energy supply through efficient energy harvesting and intelligent energy storage and distribution, solving the problems of difficult wiring and inconvenient battery replacement under complex working conditions, and significantly extending the maintenance-free operation cycle of the device.

[0052] The aforementioned structural improvements work together to simultaneously achieve high-precision monitoring, strong environmental adaptability, and long-lasting operation without the need for external power supply or complex calibration, providing a reliable and low-cost solution for intelligent monitoring of aluminum tube fluid systems.

[0053] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0054] The channel has a U-shaped axial cross-section, which facilitates the conformal embedding and fixing of the pressure sensing unit, while reducing stress concentration at the channel edges. The inner wall of the channel is provided with an anodized insulating layer to isolate the sensing unit from the aluminum tube body 1, preventing signal interference; it also improves the wear resistance and corrosion resistance of the channel's inner wall. Preferably, a capacitive pressure sensing unit can be used.

[0055] Next, the temperature sensing unit 3 is positioned in the axial projection gap area of ​​the adjacent pressure sensing unit 2 (i.e., the temperature sensing unit 3 is located in the blank area of ​​the axial projection of the pressure sensing unit 2, which is also the gap between the two adjacent pressure sensing units 2 along the axial extension direction of the aluminum tube, ensuring that their detection areas are independent). It forms an axially staggered layout with the pressure sensing unit 2, and the axial spacing of each temperature sensing unit 3 is 1.2-1.5 times the width of the pressure sensing unit 2, and the projection outline of the temperature sensing unit 3 completely falls within the axial gap range between the adjacent pressure sensing units 2.

[0056] With the above configuration, the temperature sensing unit 3 and the pressure sensing unit 2 do not overlap in the axial direction, avoiding physical interference between the two sensors. The lower limit of 1.2 times can prevent the temperature sensing unit 3 from being too densely packed, which could lead to thermal field coupling (such as mutual interference caused by sensor self-heating). The upper limit of 1.5 times can prevent the temperature sampling blind zone from being caused by excessive spacing, ensuring continuous coverage of the axial temperature gradient of the aluminum tube.

[0057] Specifically, the temperature sensing unit 3 includes:

[0058] The primary temperature sensing layer is composed of a platinum metal film continuously wound around the outer wall of the aluminum tube in a spiral shape. The platinum metal film is wound around the outer wall of the aluminum tube in a continuous spiral shape to maximize the coverage area and improve the sensitivity of temperature field sensing. As the main temperature sensing layer, it directly contacts the surface of the aluminum tube to realize continuous monitoring of temperature across the entire range.

[0059] The insulating layer is an alumina dielectric layer covering the primary temperature sensing layer. The alumina dielectric layer has high insulation properties and excellent compatibility with the platinum film. Its thickness is controlled at 5-20μm, balancing insulation strength and thermal conductivity. It is used to isolate the primary temperature sensing layer from the secondary backup layer to avoid electrical coupling interference.

[0060] And, the secondary backup layer, serving as a backup sensing channel for the primary layer, comprises multiple independent linear platinum film units arranged along the axial direction of the aluminum tube, as referenced. Figure 2 Each linear platinum film unit is connected to the signal processing component through a tapered conductive channel passing through the insulating isolation layer. The tapered conductive channel is a tapered guide hole, with its inlet end located on the upper surface of the secondary backup layer and its outlet end located in the spiral gap area on the surface of the primary temperature sensing layer.

[0061] Furthermore, the signal processing component includes a programmable gain instrumentation amplifier, the input of which is connected to the output electrode of each pressure sensing unit 2 via gold wire bonding.

[0062] The Σ-Δ analog-to-digital converter is integrated with the programmable gain instrumentation amplifier on the same ceramic package substrate. The ceramic package substrate is attached and fixed to the inner wall of the aluminum tube body 1 by a thermally conductive adhesive layer. The digital output terminal of the Σ-Δ analog-to-digital converter extends to the outer wall of the aluminum tube body 1 through a flexible circuit board. The flexible circuit board transmits the digital signal to the subsequent LoRa wireless transmission component.

[0063] Additionally, a shielding housing encloses the programmable gain instrumentation amplifier and the Σ-Δ analog-to-digital converter, with the housing grounding terminal welded to the inner wall of the aluminum tube body 1.

[0064] It is important to understand that the flexible conductive medium is a parallel bus composed of multiple strands of twisted copper wires. Each strand of twisted copper wire is independently connected to the output end of the corresponding pressure sensing unit 2 and temperature sensing unit 3, and is attached and fixed to the outer wall of the aluminum tube body 1 by a silicone layer, and extends along the axial direction of the aluminum tube in a serpentine manner.

[0065] Furthermore, the vibration energy acquisition unit is composed of multiple piezoelectric ceramic plates, each of which is arranged in a spiral along the axial direction of the aluminum tube body 1 and fixed to the outer wall surface of the aluminum tube in the vibration antinode region by an epoxy resin adhesive layer; the antinode region is determined by calibration of a laser vibration meter. Generally speaking, the vibration antinode region is a ring-shaped region in the middle section of the axial direction of the aluminum tube body 1 and is symmetrically distributed in the circumference.

[0066] The rectifier unit is a bridge rectifier circuit, which is encapsulated in a metal shielded housing with heat dissipation fins. The shielded housing is fixed to the outer wall of the aluminum tube body 1 near the vibration energy acquisition unit by bolts. The bridge rectifier circuit consists of a full-wave rectifier circuit composed of four diodes. The four diodes are encapsulated in the metal shielded housing according to the bridge topology in the prior art, and are used to convert the AC voltage output by the piezoelectric ceramic sheet into DC voltage.

[0067] The energy storage unit includes at least two supercapacitors connected in parallel and fixed to the non-vibration area of ​​the outer wall of the aluminum tube body 1 by snap-fit ​​brackets (generally, the non-vibration area is located at both ends of the axial direction of the aluminum tube body 1). An elastic buffer pad is provided between the snap-fit ​​brackets and the outer wall of the aluminum tube.

[0068] In addition, the device also includes: a LoRa wireless transmission component, which is connected to the signal processing component via an SPI interface, and a power input terminal connected to the output terminal of the energy storage unit.

[0069] Furthermore, the output of the supercapacitor is connected to a low-dropout linear regulator, which provides regulated power to the temperature compensation component, signal processing component, and LoRa wireless transmission component through independent power supply lines.

[0070] Meanwhile, the antenna of the LoRa wireless transmission component is a flexible PCB antenna, which is laid along the circumferential non-vibration area of ​​the outer wall of the aluminum tube and fixed by a high-temperature resistant adhesive layer. The antenna feed point is connected to the output terminal of the low-dropout linear regulator through a shielded cable.

[0071] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, as well as combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions.

[0072] It should be noted that any reference numerals placed between parentheses in the claims should not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. This invention can be implemented by means of hardware comprising several different components and by means of a suitably programmed computer. In claims that enumerate several means, several of these means may be embodied by the same hardware. The use of the terms first, second, third, etc., is merely for convenience of expression and does not indicate any order. These terms can be understood as part of the component names.

[0073] Furthermore, it should be noted that in the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0074] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning of the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the claims should be interpreted to include both the preferred embodiments and all changes and modifications falling within the scope of the present invention.

[0075] Obviously, those skilled in the art can make various modifications and variations to this utility model without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this utility model and their equivalents, then this utility model should also include these modifications and variations.

Claims

1. An intelligent fluid monitoring device for an aluminum tube, characterized by, include: The pressure sensing array includes at least three pressure sensing units that are embedded at equal angular intervals in annular channels opened in the thickness direction of the outer wall of the aluminum tube body, and the sensing surface of each pressure sensing unit is conformally in contact with the inner wall of the channel. The temperature compensation component includes multiple temperature sensing units that are axially spaced along the outer wall of the aluminum tube body. The signal processing component is connected to each pressure sensing unit and each temperature sensing unit via a parallel bus architecture through a flexible conductive medium. The self-powered component includes a vibration energy harvesting unit that fits into the aluminum tube body, a rectifier unit connected to the output of the vibration energy harvesting unit, and an energy storage unit that is connected to the temperature compensation component and the signal processing component respectively.

2. The intelligent fluid monitoring device for an aluminum tube of claim 1, wherein, The axial cross-section of the channel is U-shaped, and the inner wall of the channel is provided with an anodized insulating layer.

3. The intelligent fluid monitoring device for aluminum tubes as described in claim 1, characterized in that, The temperature sensing unit is located in the axial projection gap area of ​​the adjacent pressure sensing unit, forming an axially staggered layout, and the axial spacing of each temperature sensing unit is 1.2-1.5 times the width of the pressure sensing unit.

4. The intelligent fluid monitoring device for an aluminum tube of claim 1, wherein, The temperature sensing unit comprises, from the outer wall of the aluminum tube outwards, the following components: The primary temperature sensing layer is composed of a platinum metal film continuously wound in a spiral shape around the outer wall surface of the aluminum tube. The insulating layer is an alumina dielectric layer covering the primary temperature sensing layer; The secondary backup layer contains multiple independent linear platinum film units arranged along the axial direction of the aluminum tube. Each linear platinum film unit is connected to the signal processing component through a tapered conductive channel passing through the insulating isolation layer. The entrance end of the tapered conductive channel is located on the upper surface of the secondary backup layer, and the exit end is located in the spiral gap area on the surface of the primary temperature sensing layer.

5. The intelligent fluid monitoring device for an aluminum tube of claim 1, wherein, The signal processing components include: A programmable gain instrumentation amplifier, the input of which is connected to the output electrodes of each pressure sensing unit via gold wire bonding; A Σ-Δ analog-to-digital converter, integrated with a programmable gain instrumentation amplifier, is mounted on the same ceramic package substrate; The shielded housing encloses the programmable gain instrumentation amplifier and the Σ-Δ analog-to-digital converter, with the housing grounding terminal welded to the inner wall of the aluminum tube body.

6. The intelligent fluid monitoring device for an aluminum tube of claim 1, wherein, The flexible conductive medium is a parallel bus composed of multiple strands of twisted copper wires. Each strand of twisted copper wire is independently connected to the output end of the corresponding pressure sensing unit and temperature sensing unit, and is attached and fixed to the outer wall of the aluminum tube body through a silicone layer, and extends along the axial direction of the aluminum tube in a serpentine manner.

7. The intelligent fluid monitoring device for aluminum tubes as described in any one of claims 1-6, characterized in that, The vibration energy harvesting unit consists of multiple piezoelectric ceramic plates, which are arranged in a spiral along the axial direction of the aluminum tube body and fixed to the outer wall surface of the aluminum tube in the vibration antinode region. The rectifier unit is a bridge rectifier circuit, encapsulated in a metal shielded housing with heat sink fins, and the shielded housing is fixed to the outer wall of the aluminum tube body near the vibration energy acquisition unit by bolts. The energy storage unit includes at least two supercapacitors connected in parallel and fixed to the non-vibration area of ​​the outer wall of the aluminum tube by a snap-fit ​​bracket. An elastic buffer pad is provided between the snap-fit ​​bracket and the outer wall of the aluminum tube.

8. The intelligent fluid monitoring device for an aluminum tube of claim 7, wherein, Also includes: The LoRa wireless transmission component is connected to the signal processing component via the SPI interface, and the power input terminal is connected to the output terminal of the energy storage unit.

9. The intelligent fluid monitoring device for an aluminum tube of claim 8, wherein, The output of the supercapacitor is connected to a low-dropout linear regulator, which supplies power to the temperature compensation component, signal processing component, and LoRa wireless transmission component through independent power supply lines.

10. The intelligent fluid monitoring device for an aluminum tube of claim 9, wherein, The antenna of the LoRa wireless transmission component is a flexible PCB antenna, which is attached to the circumferential non-vibration area of ​​the outer wall of the aluminum tube and fixed with a high-temperature resistant adhesive layer. The antenna feed point is connected to the output terminal of the low-dropout linear regulator through a shielded cable.

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