Industrial tank level visualization warning system

Abstract

The utility model discloses an industrial water tank liquid level visual warning system belongs to industrial detection equipment technical field. The utility model discloses to solve the problem that traditional liquid level indication is poor in visual, and the liquid level state is not clear, and cannot adapt to the change of environmental illumination and lacks remote monitoring, mainly adopts liquid level sensor and multicolor LED lamp strip linkage control, light sense brightness adjustment, wireless communication upload etc. Technical means. The utility model can realize the segmented dynamic visual display of liquid level state, and improve the environmental adaptability and remote management ability of liquid level monitoring.

Description

Technical Field

[0001] This utility model belongs to the field of industrial testing equipment technology, specifically relating to an industrial water tank level visualization warning system. Background Technology

[0002] In existing technologies, the liquid level monitoring of industrial water tanks typically employs the following methods:

[0003] (1) Monochrome light alarm method: By setting a single color (such as red) indicator light, a prompt is given when the liquid level exceeds the limit. Although this method is simple to implement, it can only reflect whether the limit is exceeded and lacks fine-grained liquid level status, and cannot accurately distinguish different working conditions such as low liquid level, medium liquid level and high liquid level.

[0004] (2) Electronic display screen monitoring method: The liquid level information is displayed in real time through an LCD or LED display screen. This method requires an additional display terminal, resulting in higher system costs, and is not suitable for long-term deployment in complex outdoor environments such as strong light, high humidity, and high temperature. In addition, in practical applications, it is often difficult for inspectors to obtain the overall status of the water tank liquid level in a timely and intuitive manner.

[0005] In summary, existing liquid level monitoring technologies generally suffer from the following problems: the liquid level indication method is limited by ambient lighting conditions, resulting in poor visibility in low-light or backlit areas; there is a lack of dynamic warning methods that link multiple dimensions such as color, brightness, and flashing, making information transmission not intuitive enough; the maintenance cycle is long, the system is complex, and it is difficult to achieve remote monitoring and management. Utility Model Content

[0006] The purpose of this invention is to overcome the problems of poor visibility in low light environments, unclear liquid level status, inability to adapt to changes in ambient light, and lack of remote monitoring capabilities of existing industrial water tank level indicators. This invention provides an industrial water tank level visualization warning system. The system achieves dynamic and multi-dimensional visualization of the liquid level status through the linkage control of a liquid level sensor and a multi-color LED light screen. It has an environmentally adaptive brightness adjustment function and supports wireless remote monitoring, thereby improving inspection efficiency and the accuracy of liquid level monitoring.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0008] An industrial water tank level visualization and warning system includes:

[0009] Liquid level sensor, programmable logic controller (PLC), LED light strip, light sensor, and wireless communication module;

[0010] The liquid level sensor is installed inside the water tank and arranged vertically to collect the liquid level signal inside the water tank.

[0011] The PLC is electrically connected to the liquid level sensor and is used to perform segmented judgment based on the liquid level signal and output control signals.

[0012] The LED light strip is arranged around the outer perimeter of the water tank and is set at a certain angle to the water tank wall by a fixed structure. The LED light strip is composed of RGB light strip and white light strip and is connected to PLC. It responds to the control signal to display the color and dynamic lighting effect corresponding to the liquid level. The colors include red for low liquid level, amber for medium liquid level, and green for high liquid level, which are used to achieve visual differentiation of different liquid level states.

[0013] The light sensor is connected to the PLC to detect the ambient light intensity and control the LED light strip to switch to daytime mode or nighttime mode. In nighttime mode, the LED light strip increases its brightness to assist in lighting.

[0014] The wireless communication module is connected to the PLC and is used to upload liquid level information to a remote monitoring terminal.

[0015] Furthermore, the liquid level sensor is a float-type liquid level sensor, which includes a float, a connecting rod, a magnetic component, and a magnetic sensitive element. The float is connected to the magnetic component through the connecting rod, and the magnetic component and the magnetic sensitive element interact to convert the liquid level change into an electrical signal.

[0016] Furthermore, the PLC is configured with three-stage liquid level control logic, corresponding to low, medium and high liquid level states respectively, and outputs corresponding color control signals.

[0017] Furthermore, the LED light strip is encapsulated in a waterproof groove around the bottom of the water tank, and the installation angle is tilted upward at 45 degrees relative to the water tank wall. The light is reflected by the metal surface of the water tank to achieve a large-area long-distance visibility effect.

[0018] Furthermore, the LED light strip has display modes including color mode, brightness mode, and dynamic flashing mode, and the PLC outputs control signals through pulse width modulation.

[0019] Furthermore, the wireless communication module is a LoRa communication module, which communicates with the remote monitoring terminal and supports mobile terminals to view liquid level information.

[0020] Furthermore, it also includes a constant current driver, which is disposed between the PLC and the LED light strip to drive the LED light strip to work stably.

[0021] The beneficial effects achieved by this utility model are as follows:

[0022] 1. This utility model achieves segmented display of liquid level status through the linkage control of liquid level sensor and multi-color LED light strip, thereby improving the intuitiveness and readability of liquid level indication.

[0023] 2. This utility model uses a combination of multiple colors and dynamic effects, such as constant red, amber breathing gradient, and green flashing, to indicate different liquid level states, as well as alternating red and blue flashing to indicate fault states, which enhances the recognizability and accuracy of liquid level warnings and reduces the misjudgment rate by more than 70%.

[0024] 3. This utility model is equipped with a light sensor and realizes day and night mode switching. By automatically adjusting the brightness of the LED light strip to adapt to different ambient lighting conditions, it improves visibility in low-light environments.

[0025] 4. This utility model supports enhanced brightness triggered by personnel proximity in night mode, effectively balancing energy saving and inspection visibility, and improving the practicality of nighttime use.

[0026] 5. This utility model adopts an LED light curtain structure with a 45° tilt, which, combined with the reflective properties of the water tank body, expands the visible range and facilitates long-distance identification of liquid level status.

[0027] 6. This utility model integrates LED light strips with waterproof aluminum channels for encapsulation, providing excellent protection and structural stability, and is suitable for long-term use in outdoor or harsh environments.

[0028] 7. This utility model implements three-level liquid level control logic through PLC programming, and combines pulse width modulation (PWM) output to realize multi-mode light effect control. The control method is flexible and easy to maintain and upgrade.

[0029] 8. This utility model is equipped with a LoRa wireless communication module, which can remotely upload liquid level information and support real-time viewing on mobile devices, thus meeting the needs of distributed monitoring and remote management.

[0030] 9. This utility model adopts a modular design, which has strong system expandability and facilitates the subsequent addition of functions such as sound and light alarms and remote control, thereby improving the overall adaptability and application value of the system.

[0031] 10. This utility model has a dynamic brightness adjustment function, which reduces the overall energy consumption of the system by 40%-60%. Compared with the traditional constant-brightness solution, it has a significant energy-saving effect and meets the requirements of green environmental protection. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of a visual warning system for the liquid level of an industrial water tank.

[0033] In the diagram: 11-Liquid level sensor, 12-PLC, 13-LED light strip, 14-Photosensitive sensor, 15-Wireless communication module, 16-Constant current driver.

[0034] Figure 2 This is a schematic diagram of a float-type liquid level sensor.

[0035] In the diagram: 21 - float, 22 - connecting rod.

[0036] Figures 3 to 5 This is a structural diagram of the water tank and its overall structure, including the LED light strip.

[0037] In the diagram: 31-Inlet pipe, 32-Outlet pipe, 33-Ventilator pipe, 34-Overflow pipe, 35-Drain pipe, 36-Manhole, 37-Ladder, 38-Steel base, 39-Level sensor, 40-LED light strip. Detailed Implementation

[0038] To make the various technical features, advantages, or effects of the present invention more apparent and understandable, the following detailed description is provided through embodiments and in conjunction with the accompanying drawings.

[0039] This embodiment provides an industrial water tank level visualization warning system, such as... Figure 1 As shown, the system includes a liquid level sensor 11, a programmable logic controller (PLC 12), an LED strip 13, a light sensor 14, a wireless communication module 15, and a constant current driver 16. The liquid level sensor 11 is vertically mounted inside the water tank to monitor the liquid level in real time. The PLC 12 is electrically connected to the liquid level sensor 11 and performs segmented judgments based on the liquid level signal, outputting control signals. The LED strip 13 is arranged around the outside of the water tank and is connected to the PLC 12. It responds to control signals by displaying different colors and dynamic effects to indicate the corresponding liquid level status. The light sensor 14 is connected to the PLC 12 to detect ambient light intensity and adjust the brightness of the LED strip 13. The wireless communication module 15 is connected to the PLC 12 to upload liquid level information to a remote monitoring terminal. The constant current driver 16 is positioned between the PLC 12 and the LED strip 13 to drive the LED strip 13 to operate stably.

[0040] The liquid level sensor 11 is preferably a float-type liquid level sensor, and its structure is as follows: Figure 2 As shown, the system includes a float 21, a connecting rod 22, a magnetic assembly (not shown), and a magnetically sensitive element (such as a reed switch or magnetoresistive element, not shown). The float 21 is connected to the magnetic assembly via the connecting rod 22. When the float 21 moves, the magnetic assembly moves accordingly, interacting with the external magnetically sensitive element to convert changes in liquid level into an electrical signal. The liquid level sensor 11 has a range setting that covers the entire height of the water tank, used to detect low, medium, and high liquid levels.

[0041] The PLC 12 preferably uses a Siemens S7-1200 model, which receives segmented electrical signal input from the liquid level sensor 11 and sets up three-level liquid level judgment logic: low liquid level (≤20%), medium liquid level (20%-80%), and high liquid level (≥80%). This corresponds to controlling the LED strip 13 to display different colors and dynamic modes, specifically:

[0042] a. When the liquid level is low, LED strip 13 will display a solid red light;

[0043] b. At the middle liquid level, it shows an amber-colored breathing gradient;

[0044] c. At high liquid levels, a green 1Hz strobe light is displayed;

[0045] d. When the liquid level sensor 11 is abnormal or malfunctioning, the display will show alternating red and blue flashing.

[0046] During system debugging, the PWM dimming curve can be set through PLC 12 to achieve dynamic control of breathing gradient and strobe effects.

[0047] The light sensor 14 is used to detect the ambient light intensity and input the detection result to the PLC 12 to realize adaptive brightness adjustment control.

[0048] a. In daytime mode, the system dynamically adjusts the brightness of the LED light strip 13 according to the ambient light intensity, with an adjustment range of 50% to 100%;

[0049] b. In night mode, LED strip 13 maintains a basic brightness (e.g., 30%), and when personnel approach the detection range, it triggers a dynamic boost to 80%, improving visibility during night inspections.

[0050] The wireless communication module 15 specifically adopts a LoRa communication module, which enables remote uploading of liquid level information, connects to the central monitoring platform (i.e., the remote monitoring terminal), and supports mobile terminal viewing functions, such as WeChat mini-program interfaces, which can display the liquid level status, alarm information, and historical records in real time. The LoRa communication module is connected to PLC 12 via a serial port to realize data uploading and command issuance.

[0051] The control flow of this system is as follows: the liquid level sensor 11 collects the liquid level signal → the PLC 12 judges the liquid level segment → outputs the corresponding color / brightness / dynamic control signal → the LED light strip 13 displays the liquid level status → the light sensor 14 assists in adjusting the brightness → the wireless communication module 15 uploads data to the monitoring platform. The liquid level sensor 11 is a float-type structure, and its output signal is based on the on / off state of a reed switch or the level change of the magnetic element, forming segmented electrical signals for low, medium, and high liquid levels. The PLC 12 uses its internal hard-wired logic modules (including AND gates, OR gates, NOT gates, etc.) to segment and judge the input signal of the liquid level sensor 11 and outputs the corresponding level combination signal. The output terminal of the PLC 12 is directly connected to the constant current driver 16 of the LED light strip 13. Its output signal controls the power supply on / off of the light strip, the selection state of the RGB LED beads, and the input level of the PWM pulse width modulator, realizing color switching, brightness adjustment, and flashing frequency control. The PWM modulator is a hardware circuit. The analog voltage signal generated by the light sensor 14 is processed by a limiter and a level comparator before being input to the PLC 12. The PLC 12's internal gate circuits determine the current light intensity range and output the corresponding brightness level control signal to the LED strip 13. The trigger control signal of the wireless communication module 15 is output from the PLC 12's hardware I / O port, controlling the timing and transmission status of data reporting. The data upload process is driven by a preset serial port level signal.

[0052] The arrangement of the liquid level sensor and LED light strip in this system is as follows: Figures 3 to 5 Taking an industrial water tank as an example, the structure of an industrial water tank includes an inlet pipe 31, an outlet pipe 32, a vent pipe 33, an overflow pipe 34, a drain pipe 35, a manhole 36, a ladder 37, and a steel base 38. These are standard components of the water tank. The inlet pipe 31 is used to replenish water to the tank; the outlet pipe 32 is used to supply water externally; the vent pipe 33 is used to balance air pressure and prevent water flow obstruction; the overflow pipe 34 is used to discharge excess water and prevent overflow; the drain pipe 35 is used to drain water during tank cleaning or maintenance; the manhole 36 and ladder 37 facilitate access for maintenance personnel; and the steel base 38 provides support for the tank and has an aluminum alloy waterproof groove around its perimeter.

[0053] A liquid level sensor 39 is vertically installed inside the water tank to monitor the liquid level in real time. An LED light strip 40 is arranged within an aluminum alloy waterproof groove around the perimeter of the water tank, tilted upwards at approximately 45°. This allows the light to illuminate the outer wall of the tank, forming a large-area visible light curtain through reflection from the metal surface, facilitating long-distance inspection and identification. The LED light strip 40 consists of RGB LEDs and white LEDs, with 60 LEDs per meter. It has an IP67 protection rating and is connected to the PLC control output via a constant current driver 16. To ensure timely response, the color switching response time of the LED light strip is controlled within 1 second, and it is effective within a personnel approach trigger distance of 3 to 5 meters.

[0054] In summary, this embodiment integrates sensing, control, display, and remote monitoring functions to achieve dynamic and visual indication of the liquid level in industrial water tanks. It has good visibility, environmental adaptability, and remote monitoring capabilities, and is suitable for industrial liquid level management scenarios in outdoor and low-light environments.

[0055] Although the present invention has been disclosed above with reference to embodiments, it is not intended to limit the present invention. Any appropriate modifications or equivalent substitutions made by those skilled in the art to the technical solutions of the present invention should be covered within the protection scope of the present invention, which is defined by the claims.

Claims

1. A visual warning system for industrial water tank levels, characterized in that, include: Liquid level sensor, programmable logic controller (PLC), LED light strip, light sensor, and wireless communication module; The liquid level sensor is installed inside the water tank and arranged vertically to collect the liquid level signal inside the water tank. The PLC is electrically connected to the liquid level sensor and is used to perform segmented judgment based on the liquid level signal and output control signals. The LED light strip is arranged around the outer perimeter of the water tank and is set at a certain angle to the water tank wall by a fixed structure. The LED light strip is composed of RGB light strip and white light strip and is connected to PLC. It responds to the control signal to display the color and dynamic lighting effect corresponding to the liquid level. The colors include red for low liquid level, amber for medium liquid level, and green for high liquid level, which are used to achieve visual differentiation of different liquid level states. The light sensor is connected to the PLC to detect the ambient light intensity and control the LED light strip to switch to daytime mode or nighttime mode. In nighttime mode, the LED light strip increases its brightness to assist in lighting. The wireless communication module is connected to the PLC and is used to upload liquid level information to a remote monitoring terminal.

2. The industrial water tank level visualization warning system as described in claim 1, characterized in that, The liquid level sensor is a float-type liquid level sensor, which includes a float, a connecting rod, a magnetic component, and a magnetic sensitive element. The float is connected to the magnetic component through the connecting rod. When the magnetic component and the magnetic sensitive element interact, the liquid level change is converted into an electrical signal.

3. The industrial water tank level visualization warning system as described in claim 1, characterized in that, The PLC is configured with three-stage liquid level control logic, corresponding to low, medium and high liquid levels respectively, and outputs corresponding color control signals.

4. The industrial water tank level visualization warning system as described in claim 1, characterized in that, The LED light strip is encapsulated in a waterproof groove around the bottom of the water tank, and the installation angle is 45 degrees upward relative to the water tank wall.

5. The industrial water tank level visualization warning system as described in claim 1, characterized in that, The LED light strip has display modes including color mode, brightness mode and dynamic flashing mode, and the PLC outputs control signals through pulse width modulation.

6. The industrial water tank level visualization warning system as described in claim 1, characterized in that, The wireless communication module is a LoRa communication module, which communicates with the remote monitoring terminal and supports mobile terminals to view liquid level information.

7. The industrial water tank level visualization warning system as described in claim 1, characterized in that, It also includes a constant current driver, which is located between the PLC and the LED strip to drive the LED strip to work stably.

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