A measuring device for continuously measuring the level of material in a furnace
Patent Information
- Application Number
- CN202522357597.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-06
- Publication Date
- 2026-09-08
- Estimated Expiration
- 2035-11-06
AI Technical Summary
[0003]目前，对气化炉内料位的测量主要面临的技术难题是：炉内环境恶劣，存在高温、可燃性气体、焦油蒸汽以及粉尘等，常规的非接触式测量仪表(如超声波料位计、红外料位计)的一次测量元件(探头或透镜)在此环境下极易被焦油和粉尘污染、粘附，导致测量信号衰减或失效，无法正常工作；为应对该技术问题，现有技术中普遍采用以下几种方式，但均存在一定缺陷：
[0026] 1. This utility model places the precision grating measurement component in a clean environment outside the furnace and uses a mechanical measuring rack that extends into the furnace for contact detection, effectively avoiding the problem of traditional instruments failing due to tar and dust pollution; at the same time, the sealing structure formed by the sealing sleeve and the sealing bearing, while allowing the rack to move freely, strictly ensures the process sealing of the gasifier, prevents gas leakage, and ensures production safety.
Smart Images
Figure CN224731384U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical fields of biomass energy gas supply, charcoal production, heating, and power generation, and more specifically to a measuring device that can continuously measure the material level height inside the furnace. Background Technology
[0002] In the fields of biomass gasification, heating, and power generation, the gasifier is one of the most crucial reaction devices. Continuous and accurate measurement of the feedstock (such as biomass fuel) level inside the gasifier is essential for ensuring stable operation of the gasification process, improving gas production efficiency, and preventing safety accidents.
[0003] Currently, the main technical challenge in measuring the material level inside a gasifier is the harsh environment. The furnace contains high temperatures, flammable gases, tar vapors, and dust. Conventional non-contact measuring instruments (such as ultrasonic level gauges and infrared level gauges) are easily contaminated and adhered to by tar and dust in this environment, leading to signal attenuation or failure, and rendering them inoperable. To address this problem, existing technologies generally employ the following methods, but all have certain drawbacks:
[0004] Software-based timing estimation: This method starts timing from the end of the last feeding cycle. If no feeding occurs for an extended period (e.g., more than 10-20 minutes), the system issues a feeding timeout alarm, prompting manual inspection. This method is not based on actual measurement and cannot reflect real material level changes. It has poor accuracy and a significant risk of false alarms or missed alarms. If feeding is not timely due to an empty material level, it can easily lead to material layer burn-through, causing equipment damage or even serious accidents such as explosions.
[0005] Mechanical level gauges: such as rotary lever level switches installed inside the hopper. Although this device has a simple structure, its moving mechanical parts are also prone to jamming due to adhesion in tar-rich environments, leading to malfunctions. The control interface may display false "material present" signals, misleading operators and causing material shortages due to delayed feeding, posing a significant safety hazard.
[0006] Therefore, how to provide a device suitable for continuous measurement of the safe level of raw materials in a gasifier is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content
[0007] In view of this, the present invention provides a measuring device that can continuously measure the material level height in a furnace, aiming to solve the above-mentioned technical problems.
[0008] To achieve the above objectives, the present invention adopts the following technical solution:
[0009] A measuring device for continuously measuring the material level height inside a furnace, comprising:
[0010] A sealing sleeve, which is fixed to the top wall of the gasifier;
[0011] A drive mechanism, comprising a drive motor and a gear, wherein the drive motor is mounted on the outer wall of the sealing sleeve and its power output shaft extends to the inner side of the sealing sleeve; the gear is fixed to the end of the power output shaft of the drive motor.
[0012] A measuring rack is located inside the sealing sleeve and meshes with the gear. One end of the measuring rack is fixed with a contact sensing unit and extends into the gasifier.
[0013] The measuring component includes a grating ruler fixed on the power output shaft of the drive motor, and a grating counter for detecting the rotation of the grating ruler.
[0014] Through the above technical solution, this utility model provides a measuring device for continuously measuring the material level height inside a furnace. The driving mechanism drives the measuring rack to directly contact the material surface, and combined with a grating measuring component, converts mechanical displacement into an electrical signal, achieving continuous, direct, and accurate measurement of the material level height inside the furnace, overcoming the inaccuracy problem of software timing methods. The precision grating ruler and grating counter are placed outside the furnace, avoiding contamination from tar and dust inside the furnace and the influence of high temperatures, solving the problem of easy failure of traditional non-contact instrument probes. A sealing sleeve accommodates the measuring rack and installs the driving mechanism, providing a basic sealing and protective framework for the entire device, ensuring its rigidity and ease of installation.
[0015] Preferably, in the above-mentioned measuring device for continuously measuring the material level height in a furnace, a guide groove is provided on the inner side of the sealing sleeve, and a sliding cover is fixed to the end of the measuring rack away from the contact sensing unit. The sliding cover has a protrusion that is slidably connected to the guide groove. Through the sliding engagement between the guide groove and the protrusion on the sliding cover, precise guidance and constraint are provided for the linear movement of the measuring rack, preventing it from deflecting, jamming, or disengaging from the gears during movement, thus ensuring the repeatability and reliability of the measurement.
[0016] Preferably, in the aforementioned measuring device for continuously measuring the material level height inside the furnace, stroke limit sensors are installed on both the top and bottom surfaces of the sliding cover. These stroke limit sensors on the sliding cover provide dual, active electrical protection for measuring the rack's stroke. Before the rack reaches its limit position, the sensor sends a signal to stop the motor, preventing mechanical impact and protecting the motor and transmission mechanism, thus enhancing safety.
[0017] Preferably, in the above-mentioned measuring device for continuously measuring the material level height in a furnace, limit blocks are fixed at both ends of the guide groove. The physical limit blocks at both ends of the guide groove serve as a further safety barrier; even if the travel limit sensor fails, the limit blocks can forcibly prevent the rack from overtraveling, thus preventing damage to the device due to accidents (such as program errors or sensor malfunctions).
[0018] Preferably, in the above-mentioned measuring device for continuously measuring the material level height in a furnace, the contact sensing unit is a pressure sensor. By specifying that the contact sensing unit is a pressure sensor, the magnitude of the pressure when the rack end contacts the material can be quantitatively sensed; only when the pressure reaches a preset threshold is it determined to be valid contact and the contact stops, avoiding misjudgments caused by light touches or obstacles, thus greatly improving the accuracy and reliability of the measurement.
[0019] Preferably, in the above-mentioned measuring device for continuously measuring the material level height inside the furnace, the grating ruler is fixed on the power output shaft of the drive motor located outside the sealing sleeve. By clearly mounting the grating ruler on the motor shaft outside the furnace, keeping it away from the high temperatures, corrosive gases, and dust inside the furnace, the grating measurement system is ensured to always operate in optimal condition, guaranteeing long-term measurement stability and lifespan.
[0020] Preferably, in the above-mentioned measuring device for continuously measuring the material level height in a furnace, the grating counter is mounted on the outside of the sealing sleeve via a bracket. By independently and securely mounting the grating counter on the outside of the sealing sleeve via the bracket, it avoids directly fixing it to a motor that may vibrate. This ensures the stability of the relative position between the grating ruler and the counter, thereby obtaining a stable, jitter-free pulse signal and improving the accuracy of displacement measurement.
[0021] Preferably, in the above-mentioned measuring device for continuously measuring the material level in the furnace, the end of the sealing sleeve away from the gasifier has a sealing end cap. By setting the sealing end cap, the sealing sleeve is completely sealed, forming a complete sealed cavity together with the furnace wall mounting point, effectively preventing gas leakage from the furnace through the sealing sleeve and also preventing external air from entering, further improving the overall sealing safety of the device.
[0022] Preferably, in the aforementioned measuring device for continuously measuring the material level height inside the furnace, a sealed bearing is installed at the connection between the power output shaft of the drive motor and the sealed sleeve. This ensures that the drive motor shaft passes through the sleeve wall via the sealed bearing, guaranteeing that the motor torque can be effectively transmitted to the internal gears while blocking the path of gas leakage along the shaft.
[0023] Preferably, the aforementioned measuring device for continuously measuring the material level in a furnace further includes a controller, which is electrically connected to the drive motor, the contact sensing unit, and the grating counter. By introducing the controller and establishing an electrical connection with the drive motor, the contact sensing unit, and the grating counter, the entire measurement process is automated. The controller can process sensor signals, control the motor's start / stop and direction, calculate grating pulses, and convert them into real-time material level, thereby achieving unattended continuous measurement, data uploading, and abnormal alarms, greatly improving the equipment's intelligence level and operating efficiency.
[0024] Preferably, in the above-mentioned measuring device for continuously measuring the material level height in the furnace, the travel limit sensor is electrically connected to the controller.
[0025] As can be seen from the above technical solution, compared with the prior art, this utility model discloses a measuring device that can continuously measure the material level height in a furnace, which has the following beneficial effects:
[0026] 1. This utility model places the precision grating measurement component in a clean environment outside the furnace and uses a mechanical measuring rack that extends into the furnace for contact detection, effectively avoiding the problem of traditional instruments failing due to tar and dust pollution; at the same time, the sealing structure formed by the sealing sleeve and the sealing bearing, while allowing the rack to move freely, strictly ensures the process sealing of the gasifier, prevents gas leakage, and ensures production safety.
[0027] 2. This utility model achieves continuous, direct, and high-precision material level measurement, improving the reliability and safety of control; it accurately determines material contact through a pressure sensor at the end of the rack, replacing the extremely inaccurate software timing estimation method; its guide groove and sliding cover structure ensure smooth and accurate operation; the grating measurement component converts mechanical displacement into high-precision electrical signals without contact, making the measurement results true and reliable; in addition, the dual electrical and mechanical limit design provides redundant protection for the equipment, reducing the risk of over-travel operation.
[0028] 3. This utility model introduces a controller and electrically connects it with components such as drive, sensor, and limit switch to form a highly integrated and intelligent measurement and control system. It can automatically complete the measurement cycle, calculate the material level in real time, and interact with the upper-level control system (such as the station control system) for data exchange and abnormal alarms. Ultimately, it achieves continuous and reliable material level monitoring, providing key guarantees for the stable, efficient, and safe operation of equipment such as biomass gasification furnaces. Attached Figure Description
[0029] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0030] Figure 1 The attached figure is a cross-sectional view of the measuring device for continuously measuring the material level height inside the furnace provided by this utility model;
[0031] Figure 2 The attached figure is a top view of the sealing sleeve and sliding cover provided by this utility model.
[0032] in:
[0033] 1-Sealing sleeve; 11-Guide groove; 12-Limiting block; 13-Sealing end cap; 2-Gasifier; 3-Drive motor; 4-Gear; 5-Measuring rack; 51-Contact sensing unit; 52-Sliding cover; 521-Protrusion; 53-Stroke limit sensor; 6-Grating ruler; 7-Grating counter; 8-Sealed bearing. Detailed Implementation
[0034] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0035] See appendix Figure 1 To be continued Figure 2 This utility model discloses a measuring device that can continuously measure the height of material in a furnace.
[0036] The core of the device is a vertically mounted sealing sleeve 1, which is fixed to the top wall of the gasifier 2 via flanges or other structures. A drive motor 3 is mounted on the outer wall of the sealing sleeve 1, and its power output shaft passes through the sleeve wall via a sealed bearing 8. A gear 4 is fixed to the end of the power output shaft located inside the sealing sleeve 1.
[0037] The measuring rack 5 is housed inside the sealing sleeve 1 and meshes with the gear 4. At least one guide groove 11 is formed on the inner wall of the sealing sleeve 1. A sliding cover 52 is fixed to one end of the measuring rack 5 away from the furnace. This sliding cover 52 has a protrusion 521 that slides in conjunction with the guide groove 11, ensuring that the measuring rack 5 moves strictly in a straight line along the guide groove 11 under the drive of the gear 4, without rotation. A contact sensing unit 51 is fixed to the other end of the measuring rack 5, i.e., the detection end, and extends downwards from the sealing sleeve 1 into the interior of the gasifier 2. The top of the sealing sleeve 1 is closed by a sealing end cap 13, thus forming a complete sealed cavity together with the wall of the gasifier 2.
[0038] To ensure operational safety, travel limit sensors 53 are installed on both the top and bottom surfaces of the sliding cover 52. Additionally, physical limit blocks 12 are fixed at both ends of the guide groove 11, forming a dual mechanical and electrical limit protection system.
[0039] All measuring components are located in a clean environment outside the furnace. The grating ruler 6 (specifically a circular grating) is fixedly mounted on the power output shaft of the drive motor 3 located outside the sealing sleeve 1. The grating counter 7 (i.e., the reading head) is independently and securely mounted on the outside of the sealing sleeve 1 via a bracket, maintaining a precise relative position with the grating ruler 6, and is used to detect its rotation.
[0040] A controller (not shown in the figure) is electrically connected to the drive motor 3, the contact sensing unit 51 and the grating counter 7 via cables, forming the control core of the entire device.
[0041] The embodiments of this utility model are as follows:
[0042] 1. Initialization process:
[0043] After the device is installed, initialization is performed first to set the reference height H when the furnace is full. This can be done through automatic calibration. The controller drives the measuring rack 5 to descend from the highest position (when the sliding cover 52 touches the upper stroke limit sensor 53 or limit block 12). When the contact sensing unit 51 at the end of the measuring rack 5 contacts the raw material and reaches the pressure threshold, the controller records the reading of the grating counter 7 at this time and automatically calculates this position as the "full" reference.
[0044] 2. Routine measurement cycle:
[0045] Descending detection: The controller starts the drive motor 3, the motor shaft drives the gear 4 to rotate, and then drives the measuring rack 5 to descend at a constant speed along the guide groove 11 into the gasifier 2.
[0046] Contact Stop: When the probe end of the measuring rack 5 contacts the surface of the raw material, and the pressure detected by the contact sensing unit 51 (preferably a pressure sensor) reaches a preset threshold, a signal is immediately sent back to the controller. The controller then commands the drive motor 3 to stop rotating.
[0047] Displacement Calculation and Material Level Conversion: Throughout the descent process, the grating ruler 6, fixed on the motor shaft, rotates synchronously. The grating counter 7 continuously counts the rotation of the grating ruler 6 and outputs pulse signals to the controller. Based on the total number of received pulses and a pre-calibrated "pulse equivalent" (i.e., the linear displacement of the rack corresponding to a single pulse), the controller accurately calculates the linear displacement ΔL of the measuring rack 5 from its initial position to its stop position. Subsequently, the current real-time material level height h inside the furnace is calculated according to the formula h = H - ΔL, and this data is uploaded to the station control system.
[0048] Continuous tracking: As raw materials are consumed and the material level drops, the pressure signal from the contact sensing unit 51 disappears, and the controller will restart the above "drop-contact-measurement" cycle to achieve continuous measurement of the material level.
[0049] 3. Material loading and protection process:
[0050] The controller monitors the status of the furnace top feed valve in real time. When the feed valve opens to prepare for feeding, the controller immediately controls the drive motor 3 to reverse, quickly raising the measuring rack 5 to its highest position (initial position) to avoid impact from the feeding and protect the device. After detecting that the feed valve is closed, the controller drives the measuring rack 5 to perform a complete measurement cycle to obtain the new material level height after feeding.
[0051] 4. Security protection mechanism:
[0052] During the entire movement of the rack 5, if the travel limit sensor 53 is triggered, the controller will immediately stop the motor to achieve soft limit protection. In the event of circuit failure, the limit block 12 will act as a final safety barrier, forcibly preventing the sliding cover 52 from overtraveling and ensuring that the device is not damaged.
[0053] As can be seen from the above technical solution, this utility model achieves continuous, accurate, reliable and safe automatic measurement of material level height through the combination of ingenious mechanical structure design and photoelectric measurement technology.
[0054] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.
[0055] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A measuring device for continuously measuring the material level height inside a furnace, characterized in that, include: A sealing sleeve (1) is fixed to the top wall of the gasifier (2); The drive mechanism includes a drive motor (3) and a gear (4). The drive motor (3) is mounted on the outer wall of the sealing sleeve (1), and its power output shaft extends to the inner side of the sealing sleeve (1). The gear (4) is fixed to the end of the power output shaft of the drive motor (3). Measuring rack (5), the measuring rack (5) is located inside the sealing sleeve (1) and meshes with the gear (4), one end of the measuring rack (5) is fixed with a contact sensing unit (51) and extends into the gasifier (2); The measuring component includes a grating ruler (6) fixed on the power output shaft of the drive motor (3) and a grating counter (7) for detecting the rotation of the grating ruler (6).
2. The measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, The inner side of the sealing sleeve (1) is provided with a guide groove (11), and a sliding cover (52) is fixed at one end of the measuring rack (5) away from the contact sensing unit (51). The sliding cover (52) has a protrusion (521) that is slidably connected to the guide groove (11).
3. The measuring device for continuously measuring the material level height inside a furnace according to claim 2, characterized in that, Both the top and bottom surfaces of the sliding cover (52) are equipped with travel limit sensors (53).
4. The measuring device for continuously measuring the material level height inside a furnace according to claim 2, characterized in that, Limiting blocks (12) are fixed at both ends of the guide groove (11).
5. The measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, The contact sensing unit (51) is a pressure sensor.
6. The measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, The grating ruler (6) is fixed on the power output shaft of the drive motor (3) located outside the sealing sleeve (1).
7. The measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, The grating counter (7) is mounted on the outside of the sealing sleeve (1) via a bracket.
8. The measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, The sealing sleeve (1) has a sealing end cap (13) at the end away from the gasifier (2).
9. A measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, A sealed bearing (8) is installed at the connection between the power output shaft of the drive motor (3) and the sealed sleeve (1).
10. A measuring device for continuously measuring the material level height inside a furnace according to claim 1, characterized in that, It also includes a controller, which is electrically connected to the drive motor (3), the contact sensing unit (51) and the grating counter (7).