A photoelectric pipe level sensor

Abstract

This application relates to the field of sensor technology, specifically disclosing a photoelectric pipeline level sensor, comprising: a pipeline body; a housing structure mounted on one side of the pipeline body via connecting ribs; a PCBA board: an inner cavity matching the PCBA board is provided on one side of the housing structure, and the PCBA board is disposed within the inner cavity; an arc-shaped optical lens: disposed in the detection area of ​​the pipeline body, with the arc-shaped surface facing the interior of the pipeline body; a photoelectric emitting module and a photoelectric receiving module: mounted on one end of the PCBA board, corresponding to the detection area of ​​the pipeline body, and a telecommunications cable harness connected to the other end of the PCBA board. This application aims to solve the problems of traditional photoelectric pipeline level sensors in terms of light utilization efficiency and environmental adaptability, improving optical detection accuracy and enhancing environmental adaptability.

Description

Technical Field

[0001] This application relates to the field of sensor technology, and in particular to a photoelectric pipeline liquid level sensor. Background Technology

[0002] In fields such as industrial production, medical equipment, smart homes, and municipal water supply, real-time and accurate detection of liquid levels in pipelines is a crucial step in ensuring stable system operation and achieving automated control. For example, in chemical production, liquid level monitoring is needed to prevent pipeline overpressure and leakage; medical infusion equipment requires precise control of the remaining amount of medication; and smart home water control systems need to adjust the water supply rhythm based on liquid level data. These scenarios all place stringent requirements on the detection accuracy, response speed, and environmental adaptability of liquid level sensors.

[0003] Currently, most mainstream photoelectric pipeline level sensors on the market use planar optical lenses as the core components for light transmission and refraction. However, this traditional structure has significant technical limitations: planar lenses have weak refraction and focusing capabilities for light, resulting in generally low light utilization efficiency (usually less than 60%). A large amount of light cannot reach the detection area during propagation due to scattering and reflection losses, resulting in insufficient signal strength received by the photoelectric receiving module, which easily leads to misjudgments in scenarios with fluctuating or low liquid levels.

[0004] Meanwhile, traditional sensors lack targeted anti-interference design, allowing ambient light (such as factory lighting and direct sunlight) to easily penetrate the detection light path through the light-transmitting parts of the pipe, creating superimposed interference with the detection light and further exacerbating the difficulty of signal recognition. In operating conditions with large temperature variations (such as industrial boiler pipes and cold chain transportation pipes), temperature fluctuations can cause changes in the refractive index of the pipe material and shifts in the response characteristics of photoelectric elements. Existing sensors do not have temperature compensation mechanisms, often resulting in a linear increase in detection error with rising temperature. In environments ranging from -10℃ to 50℃, the error rate can reach over 15%.

[0005] In summary, the existing photoelectric pipeline level sensors have technical shortcomings in terms of light utilization efficiency and environmental adaptability. There is an urgent need to develop a new type of photoelectric pipeline level sensor with higher detection accuracy, stronger stability, and wider applicability through structural innovation and technological optimization. Utility Model Content

[0006] This application provides a photoelectric pipeline liquid level sensor, which aims to solve the problems of traditional photoelectric pipeline liquid level sensors in terms of light utilization efficiency and environmental adaptability.

[0007] In one embodiment, a photoelectric pipeline level sensor is provided, comprising:

[0008] Pipeline body;

[0009] Outer shell structure: Installed on one side of the pipe body via connecting stiffeners;

[0010] PCBA board: One side of the outer shell structure is provided with an inner cavity that matches the PCBA board, and the PCBA board is disposed in the inner cavity;

[0011] Arc-shaped optical lens: disposed in the detection area of ​​the main body of the pipe, with the arc-shaped surface facing the interior of the main body of the pipe;

[0012] Photoelectric transmitting module and photoelectric receiving module: installed at one end of the PCBA board, corresponding to the detection area of ​​the main body of the pipeline, and the other end of the PCBA board is connected to a telecommunications cable harness.

[0013] In one embodiment, the photoelectric pipeline level sensor further includes:

[0014] A temperature compensation unit is installed inside the pipe body and is electrically connected to a photoelectric transmitting module and a photoelectric receiving module.

[0015] In one embodiment, the main body of the pipe is made of polycarbonate material.

[0016] In one embodiment, the wavelength of the light emitted by the photoelectric emission module can be adapted and adjusted according to actual detection requirements, and after being acted upon by the arc-shaped optical lens, it can accurately cover the detection area within the main body of the pipeline.

[0017] In one embodiment, the photoelectric receiving module incorporates a signal amplification circuit that enhances the ability to identify weak signals.

[0018] In one embodiment, the compensation algorithm of the temperature compensation unit is established based on the influence of temperature on the speed of light propagation and the response characteristics of photoelectric components, and the temperature sensor data is collected in real time and the detection signal is dynamically corrected.

[0019] The beneficial effects of this application are:

[0020] Improved optical detection accuracy: The curved optical lens optimizes light refraction and convergence, significantly improving light utilization efficiency compared to traditional planar lenses. This results in a more concentrated detection beam and a better propagation path. When encountering liquid levels, the signal generated by the interaction between light and the liquid level is clearer and more easily identifiable. Combined with the low-noise, high-gain signal amplification circuit of the photoelectric receiving module, even weak light signals converted into electrical signals can be effectively amplified and accurately identified, greatly reducing the risk of misjudgment due to weak signals. This leads to more accurate liquid level detection results, ensuring stable and accurate detection in scenarios involving low, high, or dynamically changing liquid levels.

[0021] Enhanced Environmental Adaptability: The temperature compensation unit, based on the influence of temperature on light propagation and the characteristics of photoelectric components, collects temperature data in real time and dynamically corrects signal deviations. In various environments, such as high-temperature liquid level detection in industrial boiler pipelines and low-temperature liquid level monitoring in cold chain equipment, it ensures detection accuracy, overcoming the limitations of traditional sensors that are heavily temperature-dependent and broadening the sensor's applicable environment range. Simultaneously, the pipeline body is made of corrosion-resistant polycarbonate material, enabling the sensor to operate stably for extended periods in complex and harsh environments, improving environmental adaptability and reliability.

[0022] Service life and maintenance advantages: The corrosion resistance and high light transmittance of polycarbonate material reduce the decrease in light transmittance and structural damage to the pipeline body caused by material aging and corrosion, thus extending the service life of the pipeline itself. In the long run, this reduces equipment maintenance costs and ensures the continuous and stable operation of the sensor, improving the overall economic efficiency and practicality.

[0023] Application Expansion: Due to its improved detection accuracy and environmental adaptability, this sensor can cover a wider range of application scenarios. In industrial production, it can accurately monitor the liquid level in chemical pipelines and high-temperature fluid pipelines; in the medical field, it can be used for precise liquid level control in infusion pipelines and biopharmaceutical pipelines; in smart homes, it can realize the detection and management of liquid level (or fluid volume) in water supply pipelines and underfloor heating pipelines. Compared with the limited applications of traditional sensors, this utility model can meet the liquid level detection needs of multiple industries and scenarios, expanding the market application space of the sensor. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this application, 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 some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the structure of the photoelectric pipeline liquid level sensor shown in the embodiments of this application;

[0026] Figure 2 This is a cross-sectional view of the photoelectric pipeline level sensor shown in the embodiments of this application.

[0027] The labels for the attached figures are as follows:

[0028] 1. Pipe body; 2. Outer shell structure; 3. PCBA board; 4. Curved optical lens; 5. Telecommunications harness; 6. Temperature compensation unit. Detailed Implementation

[0029] The specific embodiments of this application will be further described in detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this application, but are not intended to limit the scope of this application. Similarly, the following examples are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0030] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0031] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0032] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0033] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0034] In this utility model, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0035] This application makes improvements and innovations, and proposes the following embodiments.

[0036] See Figures 1 to 2 In one embodiment, a photoelectric pipeline level sensor is provided, comprising:

[0037] Pipeline body.

[0038] Outer shell structure: Installed on one side of the pipe body via connecting stiffeners.

[0039] PCBA board: One side of the outer shell structure is provided with an inner cavity that matches the PCBA board, and the PCBA board is disposed in the inner cavity.

[0040] Arc-shaped optical lens: disposed in the detection area of ​​the main body of the pipe, with the arc-shaped surface facing the interior of the main body of the pipe.

[0041] Photoelectric transmitting module and photoelectric receiving module: installed at one end of the PCBA board, corresponding to the detection area of ​​the main body of the pipeline, and the other end of the PCBA board is connected to a telecommunications cable harness.

[0042] A temperature compensation unit is installed inside the pipe body and is electrically connected to a photoelectric transmitting module and a photoelectric receiving module.

[0043] Specifically, the main body of the pipe serves as a fluid channel, made of highly transparent and corrosion-resistant materials. It allows fluid to pass through and provides a light propagation path for detection. An arc-shaped optical lens optimizes the refraction and convergence of light, improving light utilization efficiency. The photoelectric emission module emits detection light of a specific wavelength. After passing through the arc-shaped optical lens, the light enters the main body of the pipe. The photoelectric receiving module receives the transmitted or reflected light and converts it into an electrical signal. It has a built-in signal amplification circuit to enhance the ability to identify weak signals. The temperature compensation unit includes a temperature sensor and a compensation algorithm to monitor the ambient temperature in real time and correct deviations in light propagation and photoelectric component performance caused by temperature changes.

[0044] First, the photoelectric emission module activates, emitting a specific wavelength detection beam towards the curved optical lens. Upon entering the curved optical lens, the beam is refracted and converged due to the optical properties of the curved surface, forming a more concentrated beam with an optimized propagation path, precisely targeting the detection area within the pipe body. When liquid is present in the pipe, the beam encounters the liquid level interface; some light is blocked by the liquid level, while other light is refracted due to the optical difference between the liquid medium and the air (or other non-liquid medium) within the pipe, altering the direction and intensity of the light propagation. Subsequently, the photoelectric receiving module receives the light after the liquid level effect, converting the optical signal into an electrical signal. Since the electrical signal may be weak due to the liquid level effect, the built-in low-noise, high-gain signal amplification circuit immediately... The electrical signal is amplified to improve its recognizability. Simultaneously, the temperature compensation unit's temperature sensor collects ambient temperature data in real time. Based on a pre-established compensation algorithm that considers the effects of temperature on the speed of light propagation (e.g., temperature affects the refractive index of the medium inside the pipe, changing the length and speed of the light propagation path) and the response characteristics of photoelectric elements (e.g., temperature affects the sensitivity of the photosensitive element in the photoelectric receiving module), the amplified electrical signal is dynamically corrected to eliminate temperature-induced detection deviations. Finally, the amplified and temperature-compensated electrical signal is transmitted to subsequent processing units (such as the control system and display module) to be converted into accurate liquid level detection results, enabling real-time monitoring of the liquid level inside the pipe.

[0045] The curved optical lens is embedded in the pipe body through a suitable mounting structure, ensuring that the curved surface is precisely facing the inside of the pipe body, and stably performing the function of optimizing light.

[0046] In one embodiment, the main body of the pipe is made of polycarbonate material, and the wavelength of the light emitted by the photoelectric emission module can be adapted and adjusted according to actual detection needs. After being acted upon by the arc-shaped optical lens, it can accurately cover the detection area within the main body of the pipe.

[0047] Specifically, the material's high light transmittance ensures light penetration, and its corrosion resistance allows it to adapt to different fluid environments, extending its service life. The signal amplification circuit of the photoelectric receiving module adopts a low-noise, high-gain design, effectively amplifying the electrical signal converted from weak light signals, improving detection sensitivity, and reducing the risk of misjudgment.

[0048] In one embodiment, the compensation algorithm of the temperature compensation unit is established based on the influence of temperature on the speed of light propagation and the response characteristics of photoelectric components, and the temperature sensor data is collected in real time and the detection signal is dynamically corrected.

[0049] Specifically, the temperature compensation unit, based on the influence of temperature on light propagation and the characteristics of photoelectric components, collects temperature data in real time and dynamically corrects signal deviations. In various environments, such as high-temperature and low-temperature liquid level detection in industrial boiler pipelines and low-temperature liquid level monitoring in cold chain equipment, it ensures detection accuracy, overcoming the limitations of traditional sensors that are heavily restricted by temperature, and broadening the sensor's applicable environmental range.

[0050] The above are merely optional embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application. Although embodiments of this utility model have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this utility model. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of this utility model.

Claims

1. A photoelectric pipe level sensor, characterized by include: Pipeline body; Outer shell structure: Installed on one side of the pipe body via connecting stiffeners; PCBA board: One side of the outer shell structure is provided with an inner cavity that matches the PCBA board, and the PCBA board is disposed in the inner cavity; Arc-shaped optical lens: disposed in the detection area of ​​the main body of the pipe, with the arc-shaped surface facing the interior of the main body of the pipe; Photoelectric transmitting module and photoelectric receiving module: installed at one end of the PCBA board, corresponding to the detection area of ​​the main body of the pipeline, and the other end of the PCBA board is connected to a telecommunications cable harness.

2. The photoelectric pipeline level sensor according to claim 1, characterized in that, The aforementioned photoelectric pipeline level sensor also includes: A temperature compensation unit is installed inside the pipe body and is electrically connected to a photoelectric transmitting module and a photoelectric receiving module.

3. The photoelectric pipe level sensor of claim 2, wherein, The main body of the pipe is made of polycarbonate material.

4. A photo-pipeline level sensor according to claim 2 or 3, characterised in that, The wavelength of the light emitted by the photoelectric emission module can be adapted and adjusted according to actual detection needs. After being processed by the arc-shaped optical lens, it can accurately cover the detection area inside the pipe body.

5. The photoelectric pipeline level sensor according to claim 4, characterized in that, The photoelectric receiving module has a built-in signal amplification circuit that enhances the ability to identify weak signals.

6. The photoelectric pipe level sensor of claim 5, wherein, The compensation algorithm of the temperature compensation unit is based on the influence of temperature on the speed of light propagation and the response characteristics of photoelectric components. It collects temperature sensor data in real time and dynamically corrects the detection signal.

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