An online replacement tool for a drop-in liquid level transmitter

Abstract

The utility model relates to industrial instrument maintenance technical field. Provide a kind of input type liquid level transmitter on-line replacement tool, comprising: base, intermediate mechanism, main body pipe and top cover, the intermediate mechanism is arranged on the base, the main body pipe wall is set in the outside of the intermediate mechanism and is connected with the intermediate mechanism, the top cover is arranged on the top of the intermediate mechanism, the intermediate mechanism is provided with flexible connecting piece, and the two ends of the flexible connecting piece are connected with the top cover and the input type liquid level transmitter to be replaced respectively. Solve the problem that traditional input type liquid level transmitter needs to be replaced due to failure, and the fixed connection mode is limited to stop production system first, then remove fixing components such as cable tie, bolt, etc. to take out and replace.

Description

Technical Field

[0001] This utility model relates to the field of industrial instrument maintenance technology, and more specifically, to an online replacement fixture for an immersion level transmitter. Background Technology

[0002] In industrial production processes, submersible level transmitters are key devices for monitoring the liquid level in containers, and their stable operation is directly related to the safe, controllable, and efficient operation of the production system. Whether in chemical, water treatment, energy, or manufacturing industries, accurate liquid level monitoring is crucial for ensuring continuous production processes, normal equipment operation, and preventing safety accidents. Therefore, the reliable operation of submersible level transmitters is of paramount importance to the overall safety of industrial systems.

[0003] Currently, traditional submersible level transmitters are typically installed using fixed steel pipes as support structures. Cable ties, bolts, and other fastening components are used to connect and secure the transmitter to the pipe, ensuring it remains stably submerged in the liquid being measured to achieve level monitoring. However, when a level transmitter malfunctions due to prolonged use and requires replacement, this traditional fixed connection method forces maintenance personnel to first stop the production system and then painstakingly remove the cable ties, bolts, and other fastening components before they can remove the faulty transmitter from the fixed steel pipe for replacement. Utility Model Content

[0004] The purpose of this utility model is to provide an online replacement fixture for submersible level transmitters, which aims to solve the problem that when a traditional submersible level transmitter needs to be replaced due to a malfunction, the production system must be stopped first and then the fixing components such as cable ties and bolts must be removed before it can be taken out for replacement, which is limited by the fixed connection method.

[0005] This utility model is achieved through the following technical solution:

[0006] An online replacement fixture for an immersion level transmitter includes: a base, an intermediate mechanism, a main tube, and a top cover. The intermediate mechanism is mounted on the base. The main tube wall is sleeved on the outside of the intermediate mechanism and connected to it. The top cover is mounted on the top of the intermediate mechanism. A flexible connector is provided on the intermediate mechanism. The two ends of the flexible connector are respectively connected to the top cover and the immersion level transmitter to be replaced.

[0007] Optionally, the intermediate mechanism includes several vertical baffles, which are connected to the inner side of the main tube to form several independent spaces, each of which corresponds to one of the submersible level transmitters to be replaced.

[0008] Optionally, one side of each vertical baffle is connected with the central axis of the main tube as the center line, the included angle between two adjacent vertical baffles is equal, and the other side of each vertical baffle is connected to the inner wall of the main tube to form a number of independent spaces.

[0009] Optionally, the top cover is provided with a limiting hole, and a buckle assembly is provided at the limiting hole, the buckle assembly being connected to the flexible connector.

[0010] Optionally, the top cover is provided with a cable hole through which the cable of the submersible level transmitter to be replaced passes.

[0011] Optionally, the number of the limiting holes and the cable holes corresponds to the number of the submersible level transmitters to be replaced.

[0012] Optionally, one of the limiting holes and one of the cable holes constitute a group of through holes, and several groups of the through holes are arranged in an array on the top cover with the geometric center of the top cover as the origin.

[0013] Optionally, the top cover is provided with a stop component, and a top cover is fitted on the top cover, with the stop component and the top cover being connected in cooperation.

[0014] Optionally, a counterweight is provided at the lower end of the flexible connector.

[0015] Optionally, the top and bottom ends of the main tube are provided with openings, and the bottom side of the main tube is provided with a plurality of evenly distributed flow holes.

[0016] The technical solution of this utility model has at least the following advantages and beneficial effects:

[0017] The design of the flexible connector on the intermediate mechanism connects the top cover and the submersible level transmitter to be replaced at both ends, so that the transmitter can be replaced without removing the main tube, base and other fixed support structures. Maintenance personnel can directly remove and install the transmitter by adjusting the flexible connector without stopping the production system. This effectively avoids the production interruption caused by production stoppage in traditional replacement methods and ensures continuous and stable production process.

[0018] By replacing the rigid fixing method with a flexible connection structure, the steps of removing and reinstalling the fixing components are eliminated, which greatly simplifies the replacement operation process, reduces the workload and operation time of maintenance personnel, and significantly improves the maintenance and replacement efficiency of the level transmitter.

[0019] It supports online replacement, avoiding production interruption losses caused by shutdowns, while reducing the risk of equipment failure or process abnormalities that may occur due to restarting after a shutdown, enhancing the safety and controllability of industrial production systems, and indirectly reducing economic losses caused by maintenance.

[0020] The modular design of the main tube, intermediate mechanism and other components, along with the flexible connectors, allows the tooling to be adapted to different specifications of submersible level transmitters, improving the equipment's versatility. At the same time, the overall structure is simple and easy to install, making it convenient for application in industrial scenarios in multiple fields such as chemical, water treatment, and energy, and it has high practical value. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the online replacement tooling for the submersible level transmitter according to an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram of the intermediate mechanism structure of the online replacement tooling for the submersible level transmitter according to an embodiment of the present utility model.

[0023] Figure 3 for Figure 2 A schematic diagram of the AA cross-sectional structure in the diagram;

[0024] Figure 4 This is a front view structural schematic diagram of the top cover mechanism of the online replacement tooling for the submersible level transmitter according to an embodiment of the present utility model.

[0025] Figure 5 This is a top view of the top cover mechanism of the online replacement tooling for the submersible level transmitter according to an embodiment of the present invention.

[0026] Icons: 1-Base, 2-Intermediate mechanism, 201-Flexible connector, 3-Main tube, 4-Top cover, 401-Limiting hole, 402-Cable hole, 5-Stop assembly. Detailed Implementation

[0027] The following is a detailed description of the embodiments, in conjunction with the accompanying drawings.

[0028] Reference Figure 1 , Figure 2 , Figure 4 , Figure 5 An online replacement fixture for an immersion level transmitter includes: a base 1, an intermediate mechanism 2, a main tube 3, and a top cover 4. The intermediate mechanism 2 is mounted on the base 1. The main tube 3 is sleeved on the outside of the intermediate mechanism 2 and connected to the intermediate mechanism 2. The top cover 4 is mounted on the top of the intermediate mechanism 2. A flexible connector 201 is provided on the intermediate mechanism 2. The two ends of the flexible connector 201 are connected to the top cover 4 and the immersion level transmitter to be replaced, respectively.

[0029] The base 1 can adopt a stainless steel flange structure with bolt holes on the surface. It is fixedly connected to the bottom mounting interface of the container under test by high-strength bolts, serving as the bottom support base of the tooling and ensuring the stability of the overall structure.

[0030] The intermediate mechanism 2 can be a cylindrical metal rod (such as a stainless steel rod), vertically installed at the center of the base 1 (connected by welding or bolts). The rod body has 2 to 4 pre-drilled holes evenly distributed around its circumference for threading the flexible connectors 201. The flexible connectors 201 can be made of stainless steel wire rope combined with shackles. The wire rope has high strength and good corrosion resistance, and the shackles enable quick connection or separation.

[0031] The main tube 3 can be a hollow seamless steel tube with an inner diameter larger than the outer diameter of the intermediate mechanism 2 (with a reserved gap for easy installation and guidance), and is sleeved on the outside of the intermediate mechanism 2.

[0032] The top cover 4 can be a circular metal cover plate, which is fixed to the top of the intermediate mechanism 2 by bolts. The surface is provided with a lifting lug (or screw hole) corresponding to the rope hole position of the intermediate mechanism 2, for connecting the upper end of the flexible connector 201 (the shackle and the lifting lug cooperate).

[0033] In some embodiments, the intermediate mechanism 2 includes several vertical baffles, which are connected to the inner side of the main body tube 3 to form several independent spaces. Each independent space corresponds to a submersible level transmitter to be replaced. Through the multi-independent-space design, 2 to 4 submersible level transmitters can be installed simultaneously, forming a redundant monitoring system. When a transmitter fails, maintenance personnel can use the flexible connector 201 of the corresponding space to vertically lift the faulty transmitter vertically along the independent space to the outside of the main body tube for replacement. Transmitters in other spaces continue to operate normally without stopping the production system, solving the problem of "stopping immediately upon replacement" in the traditional single-transmitter fixed method. The independent spaces are physically isolated by the vertical baffles, which can avoid mutual interference between different transmitters due to collisions and water flow impacts when the measured medium (such as liquids with impurities or flowing media) is disturbed inside the container. At the same time, the baffles reduce the direct impact of medium turbulence on the transmitter probe, making the level measurement signal more stable, especially suitable for industrial scenarios with high flow rates or suspended particles.

[0034] In some embodiments, refer to Figure 3Each vertical baffle has one side connected to the central axis of the main tube 3, with equal included angles between adjacent vertical baffles. The other side of each vertical baffle connects to the inner wall of the main tube 3, forming several independent spaces. The vertical baffles are symmetrically distributed around the central axis of the main tube, with equal included angles between adjacent baffles (e.g., 2 baffles at a 180° angle, 3 at a 120° angle, etc.), resulting in a radially symmetrical layout. This symmetrical design evenly distributes external loads (such as liquid pressure, water flow impact, and self-weight) on the main tube 3 to each vertical baffle and the inner wall of the main tube, reducing local stress concentration and improving the overall structural stability and deformation resistance of the main tube 3 and the intermediate mechanism 2. This is particularly suitable for high-velocity, high-pressure industrial fluid environments. Simultaneously, the connection between the vertical baffles and the inner wall of the main tube 3 enhances the rigidity of the main tube 3, reducing structural swaying caused by media disturbance or external vibration, and ensuring long-term reliable operation of the tooling.

[0035] In some embodiments, the top cover 4 is provided with a limiting hole 401, and a snap-fit ​​assembly is provided at the limiting hole 401, which is connected to the flexible connector 201. The limiting hole 401 provides physical limitation and guidance for the flexible connector (such as a stainless steel wire rope). When lifting or lowering the submersible level transmitter to be replaced, the flexible connector will move along the axial direction of the limiting hole, effectively limiting its lateral sway range. This avoids the flexible connector and the connected transmitter from colliding with the inner wall of the main tube 3, the vertical baffle, or other normally operating transmitters due to swaying during movement, ensuring that the transmitter can move vertically and smoothly along the preset independent space, reducing the risk of jamming, wear, or equipment interference during operation, and ensuring the smoothness and safety of maintenance operations. The snap-fit ​​assembly has the characteristics of quick connection and separation, which simplifies the connection operation between the flexible connector 201 and the top cover 4 compared to the bolt connection of the traditional shackle and lifting lug or simple shackle engagement. Maintenance personnel can quickly fix or detach the upper end of the flexible connector without the need for tools or complex operations, simply by opening and closing the clips, significantly shortening the replacement time of faulty transmitters. Especially in maintenance scenarios without shutting down the system, efficient operation can reduce the potential impact of the maintenance process on the production system and improve overall maintenance efficiency.

[0036] In some embodiments, the top cover 4 is provided with a cable hole 402, through which the cable of the submersible level transmitter to be replaced passes. Level transmitters in industrial settings require cables to transmit measurement signals or power, especially in multi-transmitter redundant monitoring systems (such as 2-4 transmitters operating simultaneously), where the number of cables is large. The cable hole 402 physically limits the cables of each transmitter, ensuring that the cables extend along a preset path from inside the main body tube 3 to outside the top cover 4. This prevents multiple cables from becoming tangled or knotted inside the main body tube 3 or during replacement operations, ensuring a clear and orderly cable layout. Simultaneously, it effectively separates the cables of faulty transmitters from those of normally operating transmitters, preventing interference during replacement and ensuring the signal transmission stability of normal transmitters.

[0037] In some embodiments, the number of limiting holes 401 and cable holes 402 corresponds to the number of submersible level transmitters to be replaced. Each submersible level transmitter has an independent limiting hole 401, allowing the flexible connector 201 (such as a stainless steel wire rope) connecting the transmitter to move along the axial direction of its dedicated limiting hole. When lifting or lowering a faulty transmitter, the flexible connector 201 and the transmitter move vertically only under the constraint of the corresponding limiting hole, effectively avoiding lateral collisions and entanglements between the flexible connectors 201 of different transmitters or between the flexible connectors 201 and other components (such as the inner wall of the main tube 3 or vertical baffles), ensuring that the faulty transmitter moves smoothly along a preset independent space, reducing the risk of jamming and wear during operation, and improving the safety and smoothness of maintenance operations.

[0038] In some embodiments, a limiting hole 401 and a cable hole 402 form a group of through holes, and several groups of through holes are arrayed on the top cover 4 with the geometric center of the top cover 4 as the origin. The array distribution with the geometric center of the top cover as the origin matches the circumferentially distributed rope holes of the intermediate mechanism 2, the symmetrical distribution of the vertical baffles (forming independent spaces), and the cylindrical structure of the main tube 3, so that the overall layout of the tooling exhibits axisymmetric characteristics. This symmetry can evenly distribute the loads generated by liquid disturbance, equipment self-weight, or external vibration to various parts of the top cover and the main tube, reduce stress concentration caused by uneven distribution of local holes, reduce the risk of structural deformation or shaking, and ensure the long-term reliable operation of the tooling in industrial environments such as high flow rate and high pressure.

[0039] In some embodiments, a stop assembly 5 is provided on the top cover 4, and a top cover is fitted onto the top cover 4. The stop assembly 5 is connected to the top cover in a cooperative manner. The stop assembly 5 can adopt a combination structure of spring clips and positioning bosses, and is evenly distributed (e.g., 3-4) along the circumferential edge of the top cover 4. Each spring clip includes a fixing seat, an elastic metal sheet, and a protruding locking head: the fixing seat is welded to the upper surface edge of the top cover 4, one end of the elastic metal sheet is connected to the fixing seat, and the other end is integrally formed with an outwardly protruding arc-shaped locking head (the surface of the locking head is rounded to reduce wear); the elastic metal sheet has a certain preload, and in its natural state, the locking head extends outward beyond the side edge of the top cover 4. At the same time, the edge of the top cover 4 is also provided with 2-3 positioning bosses (the height of which is slightly lower than the locking head of the spring clip) for circumferential positioning during the installation of the top cover, to prevent the top cover from shifting. The top cover is an inverted circular metal cover (material can be stainless steel or carbon steel with anti-corrosion coating) that fits the top cover 4. Its inner diameter is slightly larger than the outer diameter of the top cover 4 (to allow for installation clearance), and its height covers the cable hole 402, the limiting hole 401, and all exposed connecting parts (such as lifting lugs and buckle assemblies) on the top cover 4. The inner wall of the top cover has a continuous annular groove corresponding to the spring buckle position of the stop assembly 5 (the groove depth matches the protrusion height of the buckle head), and the bottom of the inner wall has a positioning groove corresponding to the positioning boss position of the top cover 4 to ensure accurate alignment during installation. The top cover can effectively prevent dust, water droplets, oil, debris, etc. from entering the area of ​​the top cover 4 in the industrial site, and prevent the cable connector in the cable hole 402, the buckle assembly at the limiting hole 401, the lifting lugs, and other key components from being contaminated or corroded. It is especially suitable for harsh environments such as chemical and water treatment industries that are humid and dusty, and extends the service life of the core components of the tooling.

[0040] In some embodiments, a counterweight is provided at the lower end of the flexible connector 201. The counterweight can be made of a high-density corrosion-resistant material, preferably 316 stainless steel (or cast iron with an anti-corrosion coating), suitable for industrial environments with humid and corrosive media such as chemical and water treatment processes. This avoids long-term immersion leading to rust and failure, ensures matching corrosion resistance with the flexible connector 201 (stainless steel wire rope), and extends the overall service life. The top of the counterweight has pre-set connection holes (such as screw holes or lifting rings), allowing for quick connection to the lower end of the flexible connector 201 (the end of the stainless steel wire rope) via shackles. The shackles enable quick assembly and disassembly of the counterweight and the flexible connector, facilitating adjustment of the counterweight specifications according to the transmitter model. Simultaneously, the bottom of the counterweight is rigidly connected to the top (or load-bearing part of the housing) of the submersible level transmitter to be replaced via bolts or special clamps, ensuring that the counterweight and transmitter form an integral load-bearing structure and preventing separation during lifting / lowering. The weight of the counterweight needs to be determined comprehensively based on the self-weight of the submersible level transmitter, the density of the liquid being measured (the effect of buoyancy), and the intensity of liquid disturbance at the site. When the submersible level transmitter is immersed in liquid, it will be subject to buoyancy, which may cause it to "float and swing" due to buoyancy imbalance during lifting or lowering. The counterweight offsets part of the buoyancy with its own weight, keeping the transmitter vertical in the liquid, avoiding tilting or jamming caused by buoyancy, ensuring smooth movement along the independent space of the main tube 3 or the guide path of the intermediate mechanism 2, and reducing operating resistance.

[0041] In some embodiments, the main tube 3 has openings at both its top and bottom ends, and a plurality of evenly distributed flow holes are provided on the bottom side of the main tube 3. The main tube 3 serves as the installation and operation carrier for the submersible level transmitter, and its core function is to work with the transmitter to achieve accurate liquid level monitoring. The opening at the bottom end of the main tube 3 and the evenly distributed flow holes on its bottom side allow the liquid in the measured container to freely enter the main tube through the openings and flow holes, ensuring that the liquid level in the main tube matches the actual liquid level in the container. For redundant monitoring systems (such as 2 to 4 transmitters with multiple independent spaces), the even distribution of the flow holes allows the liquid to flow evenly into each independent space, ensuring that the liquid level environment of each transmitter in each space is completely consistent. This avoids measurement errors caused by deviations between the liquid level in the main tube 3 and the actual liquid level in the container, or uneven liquid levels in different spaces, ensuring the consistency and reliability of monitoring data from all transmitters in the redundant system. The measured liquid in industrial settings may experience flow, fluctuations, or pressure changes (such as in chemical reaction tanks, water treatment pipelines, etc.). The bottom opening and side flow holes of the main tube 3 allow for free flow of liquid inside and outside the tube, effectively balancing the pressure difference between the inside and outside of the main tube 3 and preventing deformation or shaking of the main tube due to pressure imbalance. At the same time, the uniform distribution of the flow holes weakens the direct impact of liquid flow on the inside of the main tube 3: the liquid enters the main tube through multiple flow holes in a dispersed manner, reducing the interference of local turbulence on the transmitter probe, allowing the transmitter to operate in a relatively stable liquid environment, reducing measurement signal fluctuations caused by severe liquid disturbances, and improving the stability of monitoring data.

Claims

1. An online replacement fixture for an immersion-type level transmitter, characterized in that, include: The base (1), intermediate mechanism (2), main tube (3) and top cover (4) are provided. The intermediate mechanism (2) is set on the base (1). The main tube (3) is sleeved on the outside of the intermediate mechanism (2) and connected to the intermediate mechanism (2). The top cover (4) is set on the top of the intermediate mechanism (2). A flexible connector (201) is provided on the intermediate mechanism (2). The two ends of the flexible connector (201) are connected to the top cover (4) and the submersible level transmitter to be replaced, respectively.

2. The online replacement fixture for the submersible level transmitter as described in claim 1, characterized in that, The intermediate mechanism (2) includes several vertical baffles. The several vertical baffles are connected to the inner side of the main tube (3) to form several independent spaces. Each independent space corresponds to a submersible level transmitter to be replaced.

3. The online replacement fixture for the submersible level transmitter as described in claim 2, characterized in that, One side of each of the vertical baffles is connected with the central axis of the main tube (3) as the center line, the included angle between two adjacent vertical baffles is equal, and the other side of each vertical baffle is connected to the inner wall of the main tube (3) to form several independent spaces.

4. The online replacement fixture for the submersible level transmitter as described in claim 1, characterized in that, The top cover (4) is provided with a limiting hole (401), and a buckle assembly is provided at the limiting hole (401), which is connected to the flexible connector (201).

5. The online replacement fixture for the submersible level transmitter as described in claim 4, characterized in that, The top cover (4) is provided with a cable hole (402), through which the cable of the submersible level transmitter to be replaced passes.

6. The online replacement fixture for the submersible level transmitter as described in claim 5, characterized in that, The number of the limiting hole (401) and the cable hole (402) corresponds to the number of the submersible level transmitters to be replaced.

7. The online replacement fixture for the submersible level transmitter as described in claim 6, characterized in that, One of the limiting holes (401) and one of the cable holes (402) form a group of through holes, and several groups of the through holes are arranged in an array on the top cover (4) with the geometric center of the top cover (4) as the origin.

8. The online replacement fixture for the submersible level transmitter as described in claim 1, characterized in that, The top cover (4) is provided with a stop component (5), and a top cover is fitted on the top cover (4). The stop component (5) is connected to the top cover.

9. The online replacement fixture for the submersible level transmitter as described in claim 1, characterized in that, A counterweight is provided at the lower end of the flexible connector (201).

10. The online replacement fixture for the submersible level transmitter as described in claim 1, characterized in that, The top and bottom ends of the main tube (3) are provided with openings, and the bottom side of the main tube (3) is provided with a number of evenly distributed flow holes.

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