Magnetostrictive liquid level gauge

Abstract

The utility model relates to oilfield ground engineering metering equipment technical field especially relates to a magnetostrictive liquid level meter, technical scheme: a magnetostrictive liquid level meter, including magnetostrictive liquid level meter, heavy hammer main part, heavy hammer connecting rod, magnetic ring, heavy hammer fixed bolster, guide rod, fixed plate and connecting plate, one end of heavy hammer connecting rod is provided with heavy hammer main part, the other end of heavy hammer connecting rod is provided with magnetic ring, and heavy hammer connecting rod is with heavy hammer main part screw thread connection, and the one end welding of guide rod has heavy hammer fixed bolster, and the top of guide rod is provided with fixed plate, the utility model discloses through design iron fluorine long spraying magnetic float ball, and constructs brand-new mechanical balance system, effectively solved low temperature jam problem, and the iron fluorine long coating covered on the surface of float ball has very low friction coefficient and excellent non-adhesion characteristic, can reduce the condensation and adhesion of low temperature medium on the surface of float ball greatly, reduces the risk of adhesion of float ball and measuring rod or the inner wall of storage tank.

Description

Technical Field

[0001] This utility model relates to the field of oilfield surface engineering metering equipment technology, and in particular to a magnetostrictive liquid level gauge. Background Technology

[0002] To accelerate the company's digital transformation and meet the business needs of remote monitoring of oil well sites, the Sixth Oil Production Plant launched a pilot project in 2023 (CLJB-2023-07) to explore the operation mode of unmanned oil well sites. In the design process of real-time liquid level measurement of the 38m³ oil storage tank, taking into account factors such as capital investment and operation and maintenance, the ACL-1 magnetostrictive level gauge produced by Xi'an Ansen Intelligent Instrument Co., Ltd. was selected as the measuring instrument.

[0003] In my country's northern onshore oilfields, the annual ambient temperature ranges from -30 to 42℃. The measured medium is generally an oil-water mixture, which, depending on its density, is distributed as an upper oil-water mixture and a lower pure formation water. If the oil storage tank or oil removal tank is not continuously heated and insulated during use, the surface fluidity of the measured medium will continuously deteriorate as the natural temperature decreases, and may even lose its fluidity. This causes the magnetic float, which should move up and down the rigid level gauge rod with the liquid level change, to become stuck, resulting in false measurement results and failing to meet the requirements for continuous liquid level measurement.

[0004] This solution effectively solves the problem of low-temperature jamming by designing a Teflon-coated magnetic float and constructing a novel mechanical balancing system. The Teflon coating on the float surface has an extremely low coefficient of friction and excellent non-adhesive properties, which can significantly reduce the condensation and adhesion of low-temperature media on the float surface, reducing the risk of the float sticking to the measuring rod or the inner wall of the storage tank. At the same time, the mechanical balancing system transmits the buoyancy of the float to the main body of the counterweight through the tubing. Utilizing the balance principle of "float weight = float buoyancy + counterweight weight", the counterweight drives the magnetic ring to slide stably on the guide rod. Even if the fluidity of the medium decreases, the system can still maintain the free movement of the float through the gravity compensation mechanism, avoiding measurement distortion caused by jamming. This significantly improves the adaptability and measurement continuity of the level gauge in low-temperature environments, ensuring that it can still provide accurate data in extreme working conditions. Utility Model Content

[0005] To overcome the problem that existing extensible level gauges, when used in low-temperature environments, suffer from a significant decrease in the fluidity of the measured medium due to temperature reduction, or even complete loss of fluidity, the movement of the magnetic float on the rigid measuring rod is greatly hindered. This can easily cause the float to stick to the measuring rod or the inner wall of the tank, preventing it from rising and falling normally with changes in liquid level. This directly disrupts the force balance system, causing a serious deviation between the level gauge's output signal and the actual liquid level, resulting in false measurement results. This problem is particularly prominent in northern regions during winter or in high-latitude oilfield scenarios, severely affecting the reliability and continuity of liquid level monitoring.

[0006] The technical solution of this utility model is as follows: a magnetostrictive level gauge, comprising a magnetostrictive level gauge, a main body of a hammer, a connecting rod of a hammer, a magnetic ring, a hammer fixing bracket, a guide rod, a fixing plate, and a connecting plate. One end of the connecting rod of the hammer is provided with the main body of the hammer, and the other end of the connecting rod of the hammer is provided with a magnetic ring. The connecting rod of the hammer is threadedly connected to the main body of the hammer. One end of the guide rod is welded with a hammer fixing bracket, and the top end of the guide rod is provided with a fixing plate. One side of the fixing plate is provided with a connecting plate, and the guide rod is connected to the fixing plate through the connecting plate.

[0007] Preferably, the magnetostrictive level gauge generates current pulses that interact with the magnetic field of the float to achieve level measurement. The weight body and the float form a force balance to ensure that the float moves with the liquid level. The weight connecting rod transmits gravity to the magnetic ring to maintain system balance. The magnetic ring interacts with the current pulse of the measuring rod to transmit the float position signal. The weight fixing bracket supports the weight connecting rod and the magnetic ring to ensure stability. The guide rod provides a sliding track for the weight body or the magnetic ring to ensure measurement accuracy. The fixing plate provides a basic fixing point to support the entire device. The connecting plate enhances the structural stability.

[0008] Preferably, one end of the guide rod is equipped with a fixing clip, one side of the fixing plate is equipped with a counterweight plate, the bottom surface of the main body of the hammer is equipped with a hose, the top surface of the storage tank is equipped with a flange cover, and the top surface of the flange cover is equipped with a rain cover. In use, the fixing clip prevents the hose from slipping or falling off, the counterweight plate and the hose form a balance system to transmit buoyancy, the hose transmits buoyancy to the main body of the hammer to form dynamic balance, the flange cover seals the storage tank to protect the internal structure, and the rain cover prevents rainwater from entering and protects the electrical components.

[0009] Preferably, the surface of the counterweight plate is equipped with copper pulleys, the outside of the hose is fitted with a sealing ring, and a sealing sleeve is installed below the sealing ring. One end of the hose is equipped with a Teflon-coated float, and the surface of the flange cover is equipped with flange fixing bolts and nuts. In use, the copper pulleys reduce hose friction and ensure smooth sliding. The sealing ring and sealing sleeve seal the hose exit point to prevent media leakage. The Teflon-coated float moves with the liquid level to generate a magnetic field.

[0010] Preferably, a magnetostrictive level gauge further includes the following modules:

[0011] Signal processing and conversion module: Used to process the pulse signals generated by the magnetostrictive level gauge and convert them into readable level data;

[0012] Temperature compensation module: used to adjust measurement results according to changes in ambient temperature;

[0013] Remote monitoring and communication module: used to realize remote data transmission and centralized management;

[0014] Safety protection and alarm module: used to ensure safe operation and timely alarm in abnormal situations;

[0015] Self-diagnosis and maintenance module: Used to self-diagnose faults and provide maintenance suggestions.

[0016] Preferably, the signal processing and conversion module includes:

[0017] A11: Signal amplification unit, including a preamplifier, filter circuit and gain regulator, is used to amplify and purify pulse signals to ensure stable signal transmission;

[0018] A12: Signal conversion unit, including analog-to-digital converter, microprocessor and data interface, used to convert analog signals into digital data, process them through the microprocessor and realize external communication;

[0019] A13: Power management unit, including regulated power supply, battery backup and power monitoring circuitry, is used to provide stable power and backup power, and monitor power status to ensure continuous operation.

[0020] Preferably, the signal processing and conversion module includes the following steps when it is in operation:

[0021] S11: The circuit unit inside the magnetostrictive level gauge emits a low-energy current pulse that propagates along the measuring rod;

[0022] S12: The current pulse generates a ring magnetic field on the measuring rod, which couples with the magnetic field of the permanent magnet inside the float to form a twisted magnetic field;

[0023] S13: The tortuous magnetic field generates a return pulse signal on the measuring rod, which is transmitted in the opposite direction along the measuring rod to the circuit unit;

[0024] S14: The preamplifier enhances the weak return signal, and the filter circuit filters out high-frequency noise and improves the signal-to-noise ratio;

[0025] S15: The gain regulator automatically optimizes the signal strength, and the analog-to-digital converter converts the analog signal into a digital signal;

[0026] S16: The microprocessor calculates the liquid level height based on the time difference and sound velocity parameters;

[0027] S17: Liquid level data is transmitted to an external system via a wired or wireless interface and simultaneously stored in a data logger.

[0028] Preferably, the temperature compensation module includes:

[0029] A21: Temperature sensing unit, including thermistor, temperature transmitter and temperature calibration circuit, used to measure ambient temperature and calibrate sensor to provide accurate temperature data;

[0030] A22: Temperature compensation algorithm unit, including a compensation coefficient calculator, a data storage device and an algorithm executor, is used to calculate the compensation coefficient based on temperature data and correct the liquid level measurement results;

[0031] A23: Environmentally adaptable design unit, including insulation, heating elements and cooling fans, used to regulate internal temperature through insulation, heating or heat dissipation to adapt to different environmental conditions.

[0032] Preferably, the remote monitoring and communication module includes:

[0033] A31: Wireless communication unit, including a wireless transmitter, antenna and communication protocol converter, for transmitting liquid level data wirelessly, supporting multiple communication protocols;

[0034] A32: Wired communication interface unit, including Ethernet interface, RS485 interface and fiber optic interface, used to provide high-speed, long-distance or interference-resistant wired data transmission interface;

[0035] A33: Remote monitoring unit, including data acquisition server, monitoring interface and data analysis tools, is used to receive, store and analyze liquid level data, display the results through the monitoring interface and generate analysis reports.

[0036] As a preferred option, the safety protection and alarm module includes:

[0037] A41: Overload protection unit, including overload sensor, protection circuit and reset button, is used to detect overload conditions and automatically cut off power or limit current to ensure equipment safety;

[0038] A42: Leakage detection unit, including a leak sensor, alarm circuit and emergency shut-off valve, is used to detect media leakage, trigger an audible and visual alarm and activate the emergency shut-off valve to stop the leakage;

[0039] A43: Explosion-proof unit, including explosion-proof enclosure, explosion-proof junction box and explosion-proof certification mark, used to adopt explosion-proof enclosure and wiring design, mark explosion-proof certification information, and ensure safe use in hazardous environments.

[0040] As a preferred option, the self-diagnosis and maintenance module includes:

[0041] A51: Self-diagnostic unit, including fault detection circuit, self-diagnostic software and fault code memory, is used to detect equipment faults and store fault codes to assist in quickly troubleshooting problems;

[0042] A52: Maintenance reminder unit, including maintenance cycle counter, maintenance reminder circuit and maintenance guide memory, is used to record running time and maintenance cycle, and remind the user to perform maintenance operations when the time is due;

[0043] A53: Data recording and playback unit, including a data logger, data playback software and USB interface, is used to record historical operating data and fault information, and supports data playback and export analysis.

[0044] The beneficial effects of this utility model are:

[0045] 1. Existing rigidity level gauges, when used in low-temperature environments, experience a significant decrease in the fluidity of the measured medium due to the drop in temperature, sometimes even complete loss of fluidity. This severely hinders the movement of the magnetic float on the rigid measuring rod, making it prone to sticking to the rod or the inner wall of the tank. Consequently, the float cannot rise and fall normally with changes in liquid level, directly disrupting the force balance system and causing a severe deviation between the level gauge's output signal and the actual liquid level, resulting in false measurement results. This problem is particularly prominent in northern winters or high-latitude oilfield scenarios, seriously affecting the reliability and continuity of level monitoring. This solution effectively solves the problem of low-temperature jamming by designing a Teflon-coated magnetic float and constructing a new mechanical balance system. The Teflon coating on the surface of the float has an extremely low coefficient of friction and excellent non-adhesive properties, which can significantly reduce the condensation and adhesion of low-temperature media on the surface of the float, and reduce the risk of the float sticking to the measuring rod or the inner wall of the tank. At the same time, the mechanical balancing system transmits the buoyancy of the float to the main body of the counterweight through the tubing. Utilizing the balance principle of "float weight = float buoyancy + counterweight weight", the counterweight drives the magnetic ring to slide stably on the guide rod. Even if the fluidity of the medium decreases, the system can still maintain the free movement of the float through the gravity compensation mechanism, avoiding measurement distortion caused by jamming. This significantly improves the adaptability and measurement continuity of the level gauge in low-temperature environments, ensuring that it can still provide accurate data in extreme working conditions.

[0046] 2. Existing strictotropic level gauges experience a significant increase in viscosity when the measured medium has a high water content or low temperature. This leads to a substantial increase in adhesive resistance experienced by the float during movement. Traditional level gauges employ simple float surface treatment processes, which are insufficient to effectively resist the adhesion of viscous media. This can easily result in a viscous layer forming between the float and the measuring rod, causing sluggish or jammed float movement. This not only disrupts the stability of the force balance system but also leads to deviations in the time difference measurement of the return pulse signal, ultimately causing fluctuations or jumps in the level data and severely impacting monitoring accuracy. This solution, through the synergistic design of a Teflon-coated float and a copper pulley drive, completely solves the problem of medium adhesion. To address the issue of ball jamming caused by viscous media, the high lubricity and low surface energy of the Teflon coating allow the float to maintain low-friction movement even in viscous media, effectively reducing the adhesion and accumulation of media on the float surface. Simultaneously, in the balance system composed of the counterweight plate and tubing, copper pulleys replace traditional metal pulleys. Their smooth surface and corrosion resistance further reduce the frictional resistance of the tubing, ensuring smooth buoyancy transmission. Even with increased media viscosity, the mechanical balance system can maintain stable float movement through gravity compensation, preventing ball jamming, eliminating the root cause of signal fluctuations, and significantly improving the measurement stability and data reliability of the level gauge in complex media environments.

[0047] 3. Existing magnetostrictive level gauges, in flammable and explosive environments such as oil fields and chemical plants, are prone to static charge accumulation in their transmission components due to improper material selection during friction. If the static charge cannot be dissipated in time, it may cause electric sparks, posing an explosion risk. In addition, the insulation performance of traditional tubing is insufficient, and charge accumulation is easily generated in humid or corrosive environments, further exacerbating the explosion-proof safety hazards. This solution fundamentally solves the charge accumulation problem by adopting a transmission design using copper pulleys and plastic tubing. The copper pulleys have good conductivity and corrosion resistance. This system effectively conducts static electricity generated by friction into the grounding system, preventing charge accumulation on the pulley surface. The plastic tubing possesses excellent insulation and low friction characteristics, which not only reduces frictional resistance with the copper pulley but also blocks the conduction path of static electricity on the tubing, further reducing the risk of charge accumulation. At the same time, the explosion-proof design of the overall transmission system complies with relevant standards. Through the encapsulation of the explosion-proof housing and junction box, the electrical components are isolated from the hazardous environment, enabling the level gauge to operate safely and stably in flammable and explosive scenarios, meeting the stringent requirements for explosion-proof performance of equipment in high-risk fields such as oil fields. Attached Figure Description

[0048] Figure 1 The diagram shown is an improved installation schematic of a magnetostrictive level gauge for an oil storage tank according to this utility model.

[0049] Figure 2 The diagram shown is a frame of a magnetostrictive level gauge according to this utility model.

[0050] Figure 3 The diagram shown illustrates the workflow of a signal processing and conversion module for a magnetostrictive level gauge according to this utility model.

[0051] Explanation of reference numerals in the attached drawings: 1. Magnetostrictive level gauge; 2. Main body of the counterweight; 3. Counterweight connecting rod; 4. Magnetic ring; 5. Counterweight fixing bracket; 6. Guide rod; 7. Fixing plate; 8. Connecting plate; 9. Fixing clip; 10. Counterweight plate; 11. Pipeline; 12. Flange cover; 13. Rain cover; 14. Copper pulley; 15. Sealing ring; 16. Sealing sleeve; 17. Teflon-coated float. Detailed Implementation

[0052] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0053] Please see Figure 1 This utility model provides an embodiment: a magnetostrictive level gauge, including a magnetostrictive level gauge 1, a weight body 2, a weight connecting rod 3, a magnetic ring 4, a weight fixing bracket 5, a guide rod 6, a fixing plate 7, and a connecting plate 8. One end of the weight connecting rod 3 is provided with the weight body 2, and the other end of the weight connecting rod 3 is provided with the magnetic ring 4. The weight connecting rod 3 is threadedly connected to the weight body 2. One end of the guide rod 6 is welded with the weight fixing bracket 5, and the top end of the guide rod 6 is provided with the fixing plate 7. One side of the fixing plate 7 is provided with the connecting plate 8, and the guide rod 6 is connected to the fixing plate 7 through the connecting plate 8.

[0054] Preferably, the magnetostrictive level gauge 1 generates a current pulse, which interacts with the magnetic field of the float to achieve level measurement. The weight body 2 and the float form a force balance to ensure that the float moves with the liquid level. The weight connecting rod 3 transmits gravity to the magnetic ring 4 to maintain system balance. The magnetic ring 4 interacts with the current pulse of the measuring rod to transmit the position signal of the float. The weight fixing bracket 5 supports the weight connecting rod 3 and the magnetic ring 4 to ensure stability. The guide rod 6 provides a sliding track for the weight body 2 or the magnetic ring 4 to ensure measurement accuracy. The fixing plate 7 provides a basic fixing point to support the entire device. The connecting plate 8 enhances the structural stability.

[0055] Preferably, one end of the guide rod 6 is provided with a fixing clip 9, one side of the fixing plate 7 is provided with a counterweight plate 10, the bottom surface of the main body of the hammer is provided with a pipe rope 11, the top surface of the storage tank is provided with a flange cover 12, and the top surface of the flange cover 12 is provided with a rain cover 13. In use, the fixing clip 9 prevents the pipe rope 11 from sliding or falling off, the counterweight plate 10 and the pipe rope 11 form a balance system to transmit buoyancy, the pipe rope 11 transmits buoyancy to the main body of the hammer to form dynamic balance, the flange cover 12 seals the storage tank to protect the internal structure, and the rain cover 13 prevents rainwater from entering and protects the electrical components.

[0056] Preferably, the surface of the counterweight plate 10 is provided with a copper pulley 14, the outer side of the pipe rope 11 is fitted with a sealing ring 15, a sealing sleeve 16 is provided below the sealing ring 15, one end of the pipe rope 11 is provided with a Teflon-coated float 17, and the surface of the flange cover 12 is provided with flange fixing bolts and nuts. In use, the copper pulley 14 reduces the friction of the pipe rope 11 to ensure smooth sliding, the sealing ring 15 and the sealing sleeve 16 seal the outlet of the pipe rope 11 to prevent media leakage, and the Teflon-coated float 17 moves with the liquid level to generate a magnetic field.

[0057] Please see Figure 2-3 In this embodiment, a magnetostrictive level gauge further includes the following modules:

[0058] Signal processing and conversion module: Used to process the pulse signals generated by the magnetostrictive level gauge and convert them into readable level data;

[0059] Temperature compensation module: used to adjust measurement results according to changes in ambient temperature;

[0060] Remote monitoring and communication module: used to realize remote data transmission and centralized management;

[0061] Safety protection and alarm module: used to ensure safe operation and timely alarm in abnormal situations;

[0062] Self-diagnosis and maintenance module: Used to self-diagnose faults and provide maintenance suggestions.

[0063] Preferably, the signal processing and conversion module includes:

[0064] A11: Signal amplification unit, including a preamplifier, filter circuit and gain regulator, is used to amplify and purify pulse signals to ensure stable signal transmission;

[0065] A12: Signal conversion unit, including analog-to-digital converter, microprocessor and data interface, used to convert analog signals into digital data, process them through the microprocessor and realize external communication;

[0066] A13: Power management unit, including regulated power supply, battery backup and power monitoring circuitry, is used to provide stable power and backup power, and monitor power status to ensure continuous operation.

[0067] Preferably, the signal processing and conversion module includes the following steps when it is in operation:

[0068] S11: The circuit unit inside the magnetostrictive level gauge emits a low-energy current pulse that propagates along the measuring rod;

[0069] S12: The current pulse generates a ring magnetic field on the measuring rod, which couples with the magnetic field of the permanent magnet inside the float to form a twisted magnetic field;

[0070] S13: The tortuous magnetic field generates a return pulse signal on the measuring rod, which is transmitted in the opposite direction along the measuring rod to the circuit unit;

[0071] S14: The preamplifier enhances the weak return signal, and the filter circuit filters out high-frequency noise and improves the signal-to-noise ratio;

[0072] S15: The gain regulator automatically optimizes the signal strength, and the analog-to-digital converter converts the analog signal into a digital signal;

[0073] S16: The microprocessor calculates the liquid level height based on the time difference and sound velocity parameters;

[0074] S17: Liquid level data is transmitted to an external system via a wired or wireless interface and simultaneously stored in a data logger.

[0075] Preferably, the temperature compensation module includes:

[0076] A21: Temperature sensing unit, including thermistor, temperature transmitter and temperature calibration circuit, used to measure ambient temperature and calibrate sensor to provide accurate temperature data;

[0077] A22: Temperature compensation algorithm unit, including a compensation coefficient calculator, a data storage device and an algorithm executor, is used to calculate the compensation coefficient based on temperature data and correct the liquid level measurement results;

[0078] A23: Environmentally adaptable design unit, including insulation, heating elements and cooling fans, used to regulate internal temperature through insulation, heating or heat dissipation to adapt to different environmental conditions.

[0079] Preferably, the remote monitoring and communication module includes:

[0080] A31: Wireless communication unit, including a wireless transmitter, antenna and communication protocol converter, for transmitting liquid level data wirelessly, supporting multiple communication protocols;

[0081] A32: Wired communication interface unit, including Ethernet interface, RS485 interface and fiber optic interface, used to provide high-speed, long-distance or interference-resistant wired data transmission interface;

[0082] A33: Remote monitoring unit, including data acquisition server, monitoring interface and data analysis tools, is used to receive, store and analyze liquid level data, display the results through the monitoring interface and generate analysis reports.

[0083] As a preferred option, the safety protection and alarm module includes:

[0084] A41: Overload protection unit, including overload sensor, protection circuit and reset button, is used to detect overload conditions and automatically cut off power or limit current to ensure equipment safety;

[0085] A42: Leakage detection unit, including a leak sensor, alarm circuit and emergency shut-off valve, is used to detect media leakage, trigger an audible and visual alarm and activate the emergency shut-off valve to stop the leakage;

[0086] A43: Explosion-proof unit, including explosion-proof enclosure, explosion-proof junction box and explosion-proof certification mark, used to adopt explosion-proof enclosure and wiring design, mark explosion-proof certification information, and ensure safe use in hazardous environments.

[0087] As a preferred option, the self-diagnosis and maintenance module includes:

[0088] A51: Self-diagnostic unit, including fault detection circuit, self-diagnostic software and fault code memory, is used to detect equipment faults and store fault codes to assist in quickly troubleshooting problems;

[0089] A52: Maintenance reminder unit, including maintenance cycle counter, maintenance reminder circuit and maintenance guide memory, is used to record running time and maintenance cycle, and remind the user to perform maintenance operations when the time is due;

[0090] A53: Data recording and playback unit, including a data logger, data playback software and USB interface, is used to record historical operating data and fault information, and supports data playback and export analysis.

[0091] Example 1

[0092] Background: In winter, the ambient temperature in northern oilfields drops to -30°C, and the oil-water mixture in the storage tanks has extremely poor fluidity. Traditional magnetostrictive level gauges suffer from measurement distortion due to the float getting stuck, making it impossible to provide accurate data for oil extraction operations.

[0093] Implementation steps:

[0094] S21: Confirm the tank specifications (diameter 2m, height 3m), medium characteristics (water content 60%, viscosity 150mPa·s) and ambient temperature range (-30℃ to 10℃).

[0095] S22: Remove the top vent flange and old level gauge from the storage tank, and clean the flange mounting surface;

[0096] S23: Assemble H62 copper pulleys, rain cover, double-layer sealing rings (fluororubber) and sealing sleeves on the new flange and fix them with M16 bolts;

[0097] S24: Fix a 300mm diameter, 3.5kg Teflon-coated float to one end of the hose, leaving a 50cm adjustment length at the other end of the hose;

[0098] S25: Pass the hose through the sealing sleeve and sealing ring to ensure that the gap between the fluororubber seal and the hose is ≤0.5mm;

[0099] S26: Assemble the guide rod (φ14 PTFE tube, 2600mm long), the counterweight (304 stainless steel, 2.4kg), the magnetic ring (NdFeB permanent magnet) and the connecting plate in sequence, and fasten them with M12 bolts.

[0100] S27: Connect the end of the hose to the top of the counterweight with a stainless steel clamp, and adjust the position of the clamp so that the float is suspended in the middle of the tank;

[0101] S28: Connect the power supply to the ACL-1 magnetostrictive level gauge and observe the initial level display (preset to 1.5m).

[0102] S29: The actual liquid level in the storage tank was measured with a steel tape measure and found to be 1.52m. Record the deviation.

[0103] S210: Rotate the hose adjusting nut to shorten the hose length by 2cm, so that the level gauge reading matches the actual value (1.52m).

[0104] S211: Record liquid level data continuously for 72 hours, compare with manual measurement values, and confirm that the maximum error is ≤ ±2mm.

[0105] Data comparison table:

[0106]

[0107] Example 2

[0108] Background: The crude oil in the storage tank has a high wax content (25%) and a viscosity of 800 mPa·s. Traditional level gauges have a measurement error of >10% due to the adhesion between the float and the measuring rod, requiring frequent manual cleaning.

[0109] Implementation steps:

[0110] S31: Test crude oil viscosity (800mPa·s), pour point (22℃), and storage tank structure (arch type, 3m in diameter).

[0111] S32: Select ACL-1 type magnetostrictive level gauge (range 0-3m), with φ16 polytetrafluoroethylene guide rod;

[0112] S33: Assemble the Teflon-coated float (300mm in diameter) with the hose (4m in length), and connect the end of the hose to a 2.4kg weight.

[0113] S34: Cut the flange of the old float level gauge and clean the residual sealant;

[0114] S35: Weld a new flange (PN1.6MPa), install copper pulleys, rain cover and double sealing structure;

[0115] S36: Pass the float end hose through the sealing sleeve and adjust the float position to 10cm from the bottom of the tank;

[0116] S37: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight, and ensure that the magnetic ring can slide freely along the guide rod;

[0117] S38: Wrap the rope around the copper pulley, and fix the other end to the top of the counterweight with a stainless steel clamp;

[0118] S39: Turn on the power to the level gauge and observe the initial displayed level (preset is 0.5m).

[0119] S310: Inject a known volume of crude oil (10m³), manually measure the liquid level and rise to 1.2m, then adjust the hose length to match the displayed value;

[0120] S311: After 15 days of operation, the level gauge data was compared with the manual measurement value daily to confirm that the maximum error was ≤ ±5mm.

[0121] Data comparison table:

[0122]

[0123] Example 3

[0124] Background: Styrene storage tanks in chemical plants (explosion limits 1.1%-6.1%) require strict explosion protection. Traditional level gauges pose an explosion risk due to static electricity generated by friction of metal pulleys.

[0125] Implementation steps:

[0126] S41: Confirm that the storage tank area is of Exd IIC T6 explosion-proof rating and the ambient temperature range is (-20℃ to 50℃).

[0127] S42: Uses copper pulleys (H62 material), plastic tubing (PE material), explosion-proof housing (cast aluminum), and intrinsically safe level gauge;

[0128] S43: Determine the flange installation location (center of the top of the storage tank), the hose route, and the location of the explosion-proof junction box;

[0129] S44: Equipped with explosion-proof wrench, static grounding wire and explosion-proof putty;

[0130] S45: Disconnect the power supply and remove the old radar level gauge and non-explosion-proof components;

[0131] S46: Welded explosion-proof flange (Exd IIC T6), assembled with copper pulleys, rain cover and double-layer sealing structure;

[0132] S47: Connect the Teflon-coated float (250mm in diameter) to the hose, and connect the other end of the hose to a counterweight (2.0kg).

[0133] S48: The hose passes around the copper pulley and is fixed to the counterweight with an explosion-proof clamp to ensure no metal contact.

[0134] S49: Connect the explosion-proof power supply, initialize the level gauge parameters, and inject a known liquid level (1.8m) for calibration;

[0135] S410: Test the electrostatic grounding resistance (<10Ω) and explosion-proof gap (<0.2mm) to confirm compliance with ATEX standards;

[0136] S411: After 6 months of operation, record liquid level data and explosion-proof alarm records to confirm that there is no static electricity accumulation or false alarms.

[0137] Data comparison table:

[0138]

[0139] Example 4

[0140] Background: The temperature of heavy oil storage tanks in oil refineries often reaches 80℃. Traditional magnetostrictive level gauges suffer from signal transmission distortion due to thermal expansion of the measuring rod, and the float seal is prone to aging, resulting in a high risk of leakage.

[0141] Implementation steps:

[0142] S51: Detect the temperature (80℃), viscosity (400mPa·s) of the medium in the storage tank and the failure rate of the original level gauge (ball jamming twice a month).

[0143] S52: Uses PTFE guide rod (temperature resistance 150℃), Teflon-coated float (temperature resistance 200℃) and fluororubber sealing ring;

[0144] S53: Cut the flange of the old magnetic level gauge and clean the high-temperature residue;

[0145] S54: Welding high-temperature special flange (PN2.5MPa), assembled with copper pulleys, rain cover and double-layer sealing structure;

[0146] S55: Pass the float end hose through the sealing sleeve and adjust the float position to 20cm from the bottom of the tank.

[0147] S56: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight, and ensure that the magnetic ring can slide freely along the guide rod;

[0148] S57: The hose passes around the copper pulley, and the other end is fixed to the top of the counterweight with a high-temperature stainless steel clamp;

[0149] S58: Turn on the level gauge power, initialize parameters, and observe the initial displayed level (preset is 1.0m).

[0150] S59: Inject a known volume of heavy oil (20m³), manually measure the liquid level rise to 2.5m, and adjust the hose length to match the displayed value;

[0151] S510: Dynamic temperature compensation module, input the current ambient temperature (80℃) to calibrate the sound velocity parameters;

[0152] S511: After 30 days of operation, the level gauge data was compared with the manual measurement value daily to confirm that the maximum error was ≤ ±3mm.

[0153] Data comparison table:

[0154]

[0155] Example 5

[0156] Background: In sulfuric acid storage tanks (98% concentration), traditional stainless steel components suffer from pitting corrosion due to the highly corrosive medium, leading to float jamming and hose breakage, with an average annual failure rate of 5 times.

[0157] Implementation steps:

[0158] S61: Confirm the sulfuric acid concentration (98%), corrosion level (strong corrosion) and tank material (fiberglass).

[0159] S62: Titanium alloy float (TA2 material), polytetrafluoroethylene tubing and Hastelloy pulley (C-276) are selected.

[0160] S63: Cutting old ultrasonic level gauges and cleaning corrosion residues;

[0161] S64: Welded corrosion-resistant flange (PN1.0MPa), assembled with titanium alloy pulleys, rain cover and double-layer sealing structure;

[0162] S65: Connect the titanium alloy float to the hose, the hose goes around the Hastelloy pulley, and the other end is connected to the counterweight (made of titanium alloy).

[0163] S66: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight, and ensure that the magnetic ring can slide freely along the guide rod;

[0164] S67: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.8m).

[0165] S68: Inject a known volume of sulfuric acid (15m³), manually measure the liquid level rise to 2.0m, and adjust the hose length to match the displayed value;

[0166] S69: Activate the environmental adaptability design unit, and the heating element maintains the top temperature of the storage tank >10℃ (to prevent sulfuric acid crystallization).

[0167] S610: After 6 months of operation, the corrosion of the components is checked monthly to confirm that there is no pitting or breakage.

[0168] Data comparison table:

[0169]

[0170] Example 6

[0171] Implementation Background: A municipal water treatment plant needs to centrally monitor 50 decentralized sewage storage tanks. Traditional level gauges have unstable communication and data delays of more than 30 seconds, which cannot meet the real-time scheduling requirements.

[0172] Implementation steps:

[0173] S71: Design a LoRa wireless networking solution with a coverage radius of 5km and deploy 3 relay base stations;

[0174] S72: Uses A31 wireless communication unit (supports LoRaWAN protocol) and A32 Ethernet interface;

[0175] S73: Remove the old pressure level gauge and clean the mounting surface;

[0176] S74: Welded standard flange (PN0.6MPa), assembled with copper pulleys, rain cover and double sealing structure;

[0177] S75: Connect the Teflon-coated float to the hose, with the hose passing around the copper pulley and the other end connected to the counterweight (304 stainless steel).

[0178] S76: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight, and ensure that the magnetic ring can slide freely along the guide rod;

[0179] S77: Turn on the level gauge power, configure the wireless communication parameters (frequency band 915MHz), and bind it to the monitoring platform;

[0180] S78: The liquid level data is connected to the water plant's SCADA system via the A33 remote monitoring unit;

[0181] S79: Simulate sudden liquid level change (±0.5m / s) to verify data transmission delay <5 seconds;

[0182] S710: Enable the battery backup function of the A13 power management unit, simulate a main power failure, and confirm continuous power supply for >72 hours;

[0183] S711: After 6 months of operation, statistical data loss rate (target < 0.1%) and system availability (target > 99.9%).

[0184] Data comparison table:

[0185]

[0186] Example 7

[0187] Implementation Background: Dairy product storage tanks (temperature 4℃, pH 6.5-6.8) need to meet the 3A hygiene standard. Traditional level gauges pose a risk of product contamination due to bacterial growth in the gaps between components.

[0188] Implementation steps:

[0189] S81: Confirm that the storage tank area is an ISO 14644-1 Class 5 cleanroom, and test for surface microbial residue (<1 CFU / cm²).

[0190] S82: The float is made of 316L stainless steel with electropolishing treatment (surface roughness Ra < 0.8μm), the tubing is made of PTFE material, and the sealing ring is made of medical grade silicone.

[0191] S83: Immerse the float, hose, and flange in a 75% ethanol solution for 30 minutes, dry them, and then seal them.

[0192] S84: Welded three-piece clean flange (PN1.0MPa), assembled with copper pulleys (nickel-plated), rain cover (IP69K) and double-layer sealing structure;

[0193] S85: Pass the hose through the sealing sleeve under the laminar flow hood, connect the end to the float, and initially suspend it 5cm from the bottom of the tank.

[0194] S86: Fix the guide rod (φ12 PTFE tube) at the center of the storage tank, connect the magnetic ring and the counterweight (316L stainless steel) to ensure a design without dead angles;

[0195] S87: The tube rope passes over the copper pulley, and the other end is fixed to the counterweight with a sterile clamp, with a clamp gap of <0.1mm;

[0196] S88: Turn on the level gauge power, initialize parameters, and observe the initial displayed level (default is 0.3m).

[0197] S89: Inject simulated emulsion (viscosity 20 mPa·s), manually adjust the liquid level to 1.2 m, and verify signal stability;

[0198] S810: Use the CIP (clean-in-line) system to spray alkaline cleaning solution (pH 12), and after confirming that there is no residue, perform ATP testing (<10 RLU).

[0199] S811: Run for 3 months, with monthly testing of microbial indicators to ensure compliance with food-grade standards.

[0200] Data comparison table:

[0201]

[0202] Example 8

[0203] Background: Vaccine bulk storage tanks (temperature -20℃, cleanliness ISO 5) need to meet GMP certification. Traditional level gauges cause drug contamination due to sealing defects, with an annual scrap rate of 15%.

[0204] Implementation steps:

[0205] S91: Confirm that the design documents comply with the requirements of GMP Appendix 1 "Manufacturing of Sterile Drugs", including material certification and sterilization validation report;

[0206] S92: The float is made of 316L stainless steel electropolished (Ra<0.4μm), the hose is made of PTFE coated steel wire rope, and the sealing ring is made of fluororubber (FDA certified).

[0207] S93: Sterilize the float, hoses and flanges with VHP (vaporized hydrogen peroxide) (concentration 30g / m³, exposure time 60 minutes).

[0208] S94: Welded aseptic flange (PN0.6MPa), assembled with Hastelloy pulley (C-276), rain cover (IP68) and double-layer sealing structure;

[0209] S95: Inside the biosafety cabinet, thread the tubing through the sealing sleeve and connect the end to the float. The initial position should be 10cm from the bottom of the cabinet.

[0210] S96: Fix the guide rod (φ10 PTFE tube) at the center of the storage tank and connect the magnetic ring and the counterweight (316L stainless steel) to ensure that no particles fall off;

[0211] S97: The hose passes around the Hastelloy pulley, and the other end is fixed to the counterweight by aseptic welding. The weld is inspected by X-ray.

[0212] S98: Turn on the level gauge power, configure the wireless communication parameters (frequency band 2.4GHz), and bind it to the pharmaceutical MES system;

[0213] S99: Inject simulated drug solution (viscosity 5 mPa·s), manually adjust the liquid level to 0.8 m, and verify signal stability;

[0214] S910: Perform three VHP sterilization cycles to confirm that the components are not deformed or have degraded in performance;

[0215] S911: 12 months of operation, statistical analysis of pollution incidents (target 0 times) and data integrity (target 100%).

[0216] Data comparison table:

[0217]

[0218] Example 9

[0219] Background: The liquid oxygen chamber of the deep-sea probe (pressure 40MPa, temperature -183℃) needs to withstand extreme pressure. Traditional level gauges cause data interruption due to seal failure, with an annual failure rate of 40%.

[0220] Implementation steps:

[0221] S101: Titanium alloy TC4 float (pressure resistant 50MPa), guide rod made of Cornell 625 alloy (corrosion resistant), and metal C-ring sealing ring;

[0222] S102: Place the float, hose, and flange in liquid nitrogen (-196℃) for a cold shrinkage test to confirm that the deformation is <0.05mm;

[0223] S103: Welded ultra-high pressure flange (PN50MPa), assembled with titanium alloy pulleys, rain cover (IP68) and double-layer sealing structure;

[0224] S104: Fix the guide rod at the center of the liquid tank, connect the magnetic ring and the counterweight (titanium alloy) to ensure that the magnetic ring can slide freely along the guide rod;

[0225] S105: The hose passes around the titanium alloy pulley, and the other end is fixed to the counterweight by laser welding. The weld is then ultrasonically inspected.

[0226] S106: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.2m).

[0227] S107: Apply 40MPa water pressure in a high-pressure test tank to verify the sealing performance (leakage rate <10⁻). 9 Pa·m³ / s);

[0228] S108: Adjust the length of the hose in a liquid nitrogen environment to ensure that the error between the liquid level display and the actual value is < ±1mm;

[0229] S109: Simulate detector emission vibration (frequency 20Hz, amplitude 2mm) to confirm signal transmission stability;

[0230] S1010: Maintain a pressure of 40MPa for 72 hours and record the elongation rate of the tubing (<0.1%) and the displacement accuracy of the magnetic ring;

[0231] S1011: Receives liquid level data via a deep-sea communication system (underwater acoustic modem), with a confirmation delay of <2 seconds.

[0232] Data comparison table:

[0233]

[0234] Example 10

[0235] Background: The temperature difference between day and night in the storage tanks of desert oilfields reaches 60℃ (-10℃ to 50℃). Traditional level gauges suffer from signal transmission distortion due to thermal expansion and contraction of the measuring rod, resulting in an annual failure rate of 25%.

[0236] Implementation steps:

[0237] S111: Record the temperature fluctuation range (-10℃ to 50℃) in the storage tank area and the existing level gauge failure modes (bent probe, signal interruption).

[0238] S112: The float is coated with Teflon (temperature resistance -200℃ to 260℃), and the guide rod is made of Cornell 625 alloy (thermal expansion coefficient <1.2×10⁻). 6 / ℃);

[0239] S113: Integrates an A21 type temperature sensing unit (thermometer) into the level gauge circuit board to calibrate the temperature-velocity of sound relationship model;

[0240] S114: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (304 stainless steel), and ensure that the sliding friction coefficient of the magnetic ring is <0.1;

[0241] S115: The hose passes over the copper pulley, and the other end is fixed to the counterweight by a high-temperature stainless steel clamp with a clamp preload of 50N.

[0242] S116: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.5m).

[0243] S117: Apply a cyclic temperature of -10℃ to 50℃ to the surface of the storage tank to verify the rod deformation (<0.2mm) and signal stability;

[0244] S118: Inject simulated medium (viscosity 100 mPa·s), manually adjust the liquid level to 2.0 m, and adjust the hose length to match the displayed value;

[0245] S119: After 6 months of operation, count the number of temperature-related faults (target 0 times) and the signal interruption rate (target < 0.1%).

[0246] Data comparison table:

[0247]

[0248] Example 11

[0249] Implementation background: Chemical synthesis laboratories require liquid level accuracy of ±0.1mm. Traditional liquid level gauges have poor experimental repeatability due to mechanical errors (standard deviation >0.5mm).

[0250] Implementation steps:

[0251] S121: Confirm the tank material (glass), medium characteristics (organic solvent, viscosity 1 mPa·s), and accuracy requirements (±0.1 mm).

[0252] S122: The float is made of titanium alloy TA2 (density 4.5g / cm³), and the guide rod is made of hardened stainless steel (surface roughness Ra < 0.2μm).

[0253] S123: Fix a laser displacement sensor (resolution 0.01mm) on the top of the tank and align it with the center of the float;

[0254] S124: Enables the microprocessor (ARM Cortex-M7) of the A12 signal conversion unit and sets the sampling rate to 1kHz;

[0255] S125: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (titanium alloy), and ensure that the sliding resistance of the magnetic ring is <0.05N;

[0256] S126: The tube rope passes over the copper pulley, and the other end is fixed to the counterweight with a sterile clamp, with a clamp gap of <0.05mm;

[0257] S127: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.3m).

[0258] S128: Use a laser displacement sensor to synchronously measure the position of the float, and adjust the length of the tubing to ensure that the liquid level display error is < ±0.05mm;

[0259] S129: Simulate liquid level fluctuation (±0.2mm / s), and statistically analyze the standard deviation of 100 measurements (target <0.05mm).

[0260] Data comparison table:

[0261]

[0262] Example 12

[0263] Implementation background: 100 storage tanks across regions need to be centrally monitored. The existing system has a communication delay of >10 seconds and a fault response time of >2 hours.

[0264] Implementation steps:

[0265] S131: Deploy LoRaWAN base stations (coverage radius 15km) and configure edge computing nodes (ARM architecture, 4 cores 1.8GHz).

[0266] S132: Integrates A31 wireless communication unit (supports LoRaWAN 1.0.3 protocol) and A32 Ethernet interface (1000Mbps).

[0267] S133: Enable the A51 self-diagnostic unit (fault code library covers 50 common problems) and configure a remote firmware upgrade channel;

[0268] S134: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (304 stainless steel), and ensure that the sliding friction coefficient of the magnetic ring is <0.1;

[0269] S135: The hose passes over the copper pulley, and the other end is fixed to the counterweight by an explosion-proof clamp with a clamp preload of 30N;

[0270] S136: Turn on the level gauge power, configure the wireless communication parameters (frequency band 868MHz), and bind it to the cloud monitoring platform;

[0271] S137: Connect the liquid level data to the enterprise IoT platform through the A33 remote monitoring unit and configure real-time alarm rules (triggered by ±5% deviation of liquid level).

[0272] S138: Simulate sudden liquid level change (±0.3m) to verify the response time of remote adjustment of hose length (target <3 seconds).

[0273] S139: Disconnect the hose connection, confirm that the self-diagnostic module generates fault code (E012) and triggers a remote alarm.

[0274] Data comparison table:

[0275]

[0276] Example 13

[0277] Background: The ambient temperature of oil and gas storage tanks in the Arctic is as low as -50°C. Traditional level gauges suffer from measurement distortion due to float jamming and probe embrittlement, resulting in an annual failure rate of 30%.

[0278] Implementation steps:

[0279] S141: Record the temperature fluctuation range (-50℃ to -20℃) in the storage tank area and the existing level gauge failure modes (float icing, probe breakage).

[0280] S142: The float is coated with Teflon (temperature resistance -200℃ to 260℃), the guide rod is made of Cornell 625 alloy (resistant to low temperature embrittlement), and the pulley is made of copper (resistant to -50℃).

[0281] S143: An integrated resistance wire heating strip (power 50W / m) is installed inside the guide rod, and a temperature controller is set (set temperature -10℃).

[0282] S144: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (304 stainless steel), and ensure that the sliding friction coefficient of the magnetic ring is <0.1;

[0283] S145: The hose passes over the copper pulley, and the other end is fixed to the counterweight by a high-temperature stainless steel clamp with a clamp preload of 50N.

[0284] S146: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.5m).

[0285] S147: Apply a cyclic temperature of -50℃ to -20℃ to the surface of the storage tank to verify the rod deformation (<0.2mm) and signal stability;

[0286] S148: Inject simulated medium (viscosity 10 mPa·s), manually adjust the liquid level to 2.0 m, and adjust the hose length to match the displayed value;

[0287] S149: After 6 months of operation, count the number of temperature-related faults (target 0 times) and the signal interruption rate (target < 0.1%).

[0288] Data comparison table:

[0289]

[0290] Example 14

[0291] Implementation Background: Nuclear power plant waste liquid storage tanks need to withstand gamma radiation (dose rate 10). 4 (Gy / h), traditional electronic components are susceptible to radiation damage, leading to data interruption, and annual maintenance costs reach ¥200,000.

[0292] Implementation steps:

[0293] S151: The liquid level gauge housing is made of lead-glass composite shielding layer (5mm thick), and the internal circuit is coated with anti-radiation coating (such as polyimide).

[0294] S152: The float is made of titanium alloy TC4 (radiation resistance dose 10). 6 Gy), the tubing is made of carbon fiber reinforced plastic (CFRP), and the sealing ring is made of fluororubber (resistant to radiation aging);

[0295] S153: Integrated dual-channel signal processing module (A11-A12), with a fault switching switch to ensure automatic switching in case of single-channel failure;

[0296] S154: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (Hastelloy C-276), and ensure that the sliding resistance of the magnetic ring is <0.05N;

[0297] S155: The hose passes around the titanium alloy pulley, and the other end is fixed to the counterweight by laser welding. The weld is inspected by X-ray.

[0298] S156: Turn on the power to the level gauge, configure the wireless communication parameters (frequency band 433MHz), and bind it to the nuclear power plant monitoring platform;

[0299] S157: Exposure to a cobalt-60 radiation source for 72 hours to verify the functionality of electronic components (signal transmission rate > 99.9%).

[0300] S158: Inject simulated waste liquid (pH 12), manually adjust the liquid level to 1.5m, and adjust the hose length to match the displayed value;

[0301] S159: After 12 months of operation, count the number of radiation-related failures (target 0 times) and data integrity (target 100%).

[0302] Data comparison table:

[0303]

[0304] Example 15

[0305] Implementation background: Semiconductor ultrapure water storage tank (resistivity 18.2MΩ·cm) requires a liquid level accuracy of ±0.05mm. Traditional liquid level gauges suffer from reduced product yield (<95%) due to contamination and mechanical errors.

[0306] Implementation steps:

[0307] S161: Assembly shall be carried out in an ISO 14644-1 Class 1 cleanroom, with operators wearing cleanroom suits and using ultrapure water to clean the components;

[0308] S162: The float is made of PTFE (food grade certified), the guide rod is made of hardened glass (surface roughness Ra < 0.1μm), and the sealing ring is made of perfluoroether rubber (FFKM).

[0309] S163: Integrated laser displacement sensor (resolution 0.01mm), linked with the level gauge signal processing module (A12) to achieve automatic calibration;

[0310] S164: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (316L stainless steel), and ensure that the sliding resistance of the magnetic ring is <0.02N;

[0311] S165: The tube rope passes around the copper pulley, and the other end is fixed to the counterweight with a sterile clamp, with a clamp gap of <0.05mm;

[0312] S166: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.3m).

[0313] S167: Use a laser displacement sensor to synchronously measure the float position, and adjust the rope length to ensure that the liquid level display error is <±0.02mm;

[0314] S168: Perform microbial challenge testing (inoculation 10) 6 (CFU / mL bacteria) confirmed that no biofilm had formed on the level gauge surface;

[0315] S169: After 12 months of operation, calculate the product yield (target > 99.9%) and cleaning and maintenance frequency (target once a month).

[0316] Data comparison table:

[0317]

[0318] Example 16

[0319] Background: The float of the pulp storage tank (viscosity 5000mPa·s) in the paper mill is stuck due to fiber entanglement, resulting in an annual maintenance cost of ¥150,000. The blockage rate of traditional level gauges is >40%.

[0320] Implementation steps:

[0321] S171: Detect pulp viscosity (5000 mPa·s), fiber content (3%), and existing level gauge failure modes (float jamming, signal interruption);

[0322] S172: The float is coated with Teflon (350mm in diameter), the guide rod is made of hardened stainless steel (surface roughness Ra < 0.3μm), and the pulley is made of copper (anti-static).

[0323] S173: Install a stainless steel filter screen (2mm aperture) at the guide rod inlet to prevent large fibers from entering;

[0324] S174: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (304 stainless steel), and ensure that the sliding friction coefficient of the magnetic ring is <0.15;

[0325] S175: The hose passes over the copper pulley, and the other end is fixed to the counterweight by a high-temperature stainless steel clamp with a clamp preload of 60N.

[0326] S176: Turn on the level gauge power, initialize the parameters, and observe the initial displayed level (preset is 0.8m).

[0327] S177: Inject simulated pulp (viscosity 5000 mPa·s), manually adjust the liquid level to 2.5 m, and verify signal stability;

[0328] S178: Continuous operation for 72 hours, counting the number of fiber blockages (target 0 times) and signal interruption rate (target < 0.2%).

[0329] S179: After 6 months of operation, statistics on maintenance frequency (target: once per month) and cost (target: ¥30,000 per year).

[0330] Data comparison table:

[0331]

[0332] Example 17

[0333] Background: Lithium battery electrolyte storage tanks (flammable and explosive, CO concentration > 30%) need to be explosion-proof and corrosion-resistant. Traditional level gauges malfunction due to static electricity or corrosion, with an annual failure rate of 25%.

[0334] Implementation steps:

[0335] S181: Selects an intrinsically safe explosion-proof level gauge (Exd IIC T6), with a cast aluminum housing and an explosion-proof junction box;

[0336] S182: The float is made of titanium alloy TA2 (resistant to electrolyte corrosion), the hose is made of PTFE-coated steel wire rope, and the sealing ring is made of perfluoroether rubber (FFKM).

[0337] S183: Integrated NB-IoT communication module (power consumption <50mA), set to wake up timed (upload data once per hour);

[0338] S184: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (Hastelloy C-276), and ensure that the sliding resistance of the magnetic ring is <0.05N;

[0339] S185: The hose passes around the titanium alloy pulley, and the other end is fixed to the counterweight by laser welding. The weld is inspected by X-ray.

[0340] S186: Turn on the power to the level gauge, configure the NB-IoT parameters (band 8), and bind it to the battery factory monitoring platform;

[0341] S187: Explosion-proof performance verified in a methane-air mixture (no leakage at 1.5 times the explosion pressure);

[0342] S188: Immerse the float in electrolyte (LiPF6) for 72 hours and confirm that there is no corrosion on the surface;

[0343] S189: After 12 months of operation, count the number of explosion-proof related failures (target 0 times) and data integrity (target 100%).

[0344] Data comparison table:

[0345]

[0346] Example 18

[0347] Background: Agricultural cooperatives need to remotely monitor fertilizer solution storage tanks (pH 2-3, highly corrosive), but rural 4G signals are weak and traditional systems have data delays of >30 seconds.

[0348] Implementation steps:

[0349] S191: The float is made of PTFE (acid corrosion resistant), the guide rod is made of fiberglass (pH value 2-3 resistant), and the sealing ring is made of fluororubber (aging resistant).

[0350] S192: Integrated LoRaWAN module (470MHz band), sleep mode set (power consumption <10μA);

[0351] S193: Equipped with a 20W solar panel and a lithium battery (capacity 100Ah), ensuring it can still work even after 7 consecutive days without sunlight;

[0352] S194: Fix the guide rod at the center of the storage tank, connect the magnetic ring and the counterweight (304 stainless steel), and ensure that the sliding friction coefficient of the magnetic ring is <0.1;

[0353] S195: The hose passes over the copper pulley, and the other end is fixed to the counterweight by an explosion-proof clamp with a clamp preload of 40N;

[0354] S196: Turn on the power to the level gauge, configure the LoRaWAN parameters (spreading factor SF7), and bind it to the agricultural monitoring platform;

[0355] S197: Verify communication distance (target > 5km) and data latency (target < 5 seconds) in areas without 4G signal.

[0356] S198: Immerse the float in a fertilizer solution (pH 2) for 72 hours and confirm that there is no swelling or cracking on the surface;

[0357] S199: Run for 12 months, and collect statistics on the number of interruptions (target 0 times) and battery life (target > 3 years).

[0358] Data comparison table:

[0359]

[0360] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A magnetostrictive level gauge; characterized in that: It includes a magnetostrictive level gauge (1), a hammer body (2), a hammer connecting rod (3), a magnetic ring (4), a hammer fixing bracket (5), a guide rod (6), a fixing plate (7), and a connecting plate (8). One end of the hammer connecting rod (3) is provided with the hammer body (2), and the other end of the hammer connecting rod (3) is provided with the magnetic ring (4). The hammer connecting rod (3) is threadedly connected to the hammer body (2), and one end of the guide rod (6) is welded with the hammer fixing bracket (5).

2. The magnetostrictive level gauge according to claim 1, characterized in that: A fixing plate (7) is provided at the top of the guide rod (6), and a connecting plate (8) is provided on one side of the fixing plate (7). The guide rod (6) is connected to the fixing plate (7) through the connecting plate (8).

3. The magnetostrictive level gauge according to claim 1, characterized in that: A fixing clip (9) is provided at one end of the guide rod (6), and a counterweight plate (10) is provided on one side of the fixing plate (7).

4. A magnetostrictive level gauge according to claim 1, characterized in that: The bottom surface of the main body of the counterweight (2) is provided with a pipe rope (11), the top surface of the storage tank is provided with a flange cover (12), and the top surface of the flange cover (12) is provided with a rain cover (13).

5. A magnetostrictive level gauge according to claim 2, characterized in that: The surface of the counterweight plate (10) is provided with a copper pulley (14), the outer side of the pipe rope (11) is provided with a sealing ring (15), the bottom of the sealing ring (15) is provided with a sealing sleeve (16), one end of the pipe rope (11) is provided with a Teflon-coated float (17), and the surface of the flange cover (12) is provided with flange fixing bolts and nuts.

6. A magnetostrictive level gauge according to claim 3, characterized in that: A magnetostrictive level gauge further comprises the following modules: Signal processing and conversion module: Used to process the pulse signals generated by the magnetostrictive level gauge and convert them into readable level data; Temperature compensation module: used to adjust measurement results according to changes in ambient temperature; Remote monitoring and communication module: used to realize remote data transmission and centralized management; Safety protection and alarm module: used to ensure safe operation and timely alarm in abnormal situations; Self-diagnosis and maintenance module: Used to self-diagnose faults and provide maintenance suggestions.

7. A magnetostrictive level gauge according to claim 4, characterized in that: The signal processing and conversion module includes: A11: Signal amplification unit, including a preamplifier, filter circuit and gain regulator, is used to amplify and purify pulse signals to ensure stable signal transmission; A12: Signal conversion unit, including analog-to-digital converter, microprocessor and data interface, used to convert analog signals into digital data, process them through the microprocessor and realize external communication; A13: Power management unit, including regulated power supply, battery backup and power monitoring circuitry, is used to provide stable power and backup power, and monitor power status to ensure continuous operation.

8. A magnetostrictive level gauge according to claim 4, characterized in that: The temperature compensation module includes: A21: Temperature sensing unit, including thermistor, temperature transmitter and temperature calibration circuit, used to measure ambient temperature and calibrate sensor to provide accurate temperature data; A22: Temperature compensation algorithm unit, including a compensation coefficient calculator, a data storage device and an algorithm executor, is used to calculate the compensation coefficient based on temperature data and correct the liquid level measurement results; A23: Environmentally adaptable design unit, including insulation, heating elements and cooling fans, used to regulate internal temperature through insulation, heating or heat dissipation to adapt to different environmental conditions.

9. A magnetostrictive level gauge according to claim 4, characterized in that: The remote monitoring and communication module includes: A31: Wireless communication unit, including a wireless transmitter, antenna and communication protocol converter, for transmitting liquid level data wirelessly, supporting multiple communication protocols; A32: Wired communication interface unit, including Ethernet interface, RS485 interface and fiber optic interface, used to provide high-speed, long-distance or interference-resistant wired data transmission interface; A33: Remote monitoring unit, including data acquisition server, monitoring interface and data analysis tools, is used to receive, store and analyze liquid level data, display the results through the monitoring interface and generate analysis reports.

10. A magnetostrictive level gauge according to claim 4, characterized in that: The security protection and alarm module includes: A41: Overload protection unit, including overload sensor, protection circuit and reset button, is used to detect overload conditions and automatically cut off power or limit current to ensure equipment safety; A42: Leakage detection unit, including a leak sensor, alarm circuit and emergency shut-off valve, is used to detect media leakage, trigger an audible and visual alarm and activate the emergency shut-off valve to stop the leakage; A43: Explosion-proof unit, including explosion-proof enclosure, explosion-proof junction box and explosion-proof certification mark, used to adopt explosion-proof enclosure and wiring design, mark explosion-proof certification information, and ensure safe use in hazardous environments.

11. A magnetostrictive level gauge according to claim 4, characterized in that: The self-diagnosis and maintenance module includes: A51: Self-diagnostic unit, including fault detection circuit, self-diagnostic software and fault code memory, is used to detect equipment faults and store fault codes to assist in quickly troubleshooting problems; A52: Maintenance reminder unit, including maintenance cycle counter, maintenance reminder circuit and maintenance guide memory, is used to record running time and maintenance cycle, and remind the user to perform maintenance operations when the time is due; A53: Data recording and playback unit, including a data logger, data playback software and USB interface, is used to record historical operating data and fault information, and supports data playback and export analysis.

Images