A fullness sensor, alarm device

Abstract

The application discloses a full-grain sensor, and aims at solving the problem of insufficient sensitivity of a traditional sensor. The sensor comprises a main body seat with an isolation chamber, a PCB plate with a magnetic induction element, a cover plate with a boss, a leather cup fixed by a pressing plate, a support plate fixed to the inner side of the leather cup, a magnet arranged in the support plate, and a spring connecting the boss and the support plate. The leather cup, the support plate and the magnet constitute a movable assembly which can move under pressure and be reset by the spring. When the material accumulation exerts pressure on the leather cup, the movable assembly drives the magnet to displace, changes the relative position of the magnetic induction element on the PCB plate, and outputs an electric signal. The full-grain sensor has the advantages of compact structure, non-contact measurement by magnetic induction, spring reset, significantly improved detection sensitivity and reliability, and is suitable for full-material detection in environments such as grain stores.

Description

Technical Field

[0001] This invention relates to the field of material detection technology, specifically to a grain full detection sensor for storage equipment such as grain silos and hoppers. Background Technology

[0002] In the fields of grain storage, processing, and transportation, real-time and accurate detection of whether the material in the silo has reached the preset full position is crucial. This prevents material overflow, improves automation levels, and ensures production safety. Existing grain fullness detection technologies mainly include mechanical, capacitive, and tuning fork types. Mechanical probes (such as baffle-type probes) are in direct contact with the material and are easily jammed or damaged by material accumulation and impact, resulting in low reliability. Although capacitive or tuning fork sensors are non-contact or vibration-based, they are sensitive to the installation environment, the dielectric constant of the material, or the bulk density, and are also costly. Furthermore, their long-term stability is poor in dusty and humid grain silo environments. Therefore, there is an urgent need for a grain fullness sensor that is simple in structure, has strong anti-interference capabilities, is reliable in operation, and has a long lifespan. Summary of the Invention

[0003] The present invention aims to overcome the shortcomings of the prior art and provide a grain full sensor that is compact, well-sealed, sensitive, and durable.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a grain full sensor, comprising a main body, a PCB board, a cover plate, a spring, a support plate, a magnet, a cup, and a pressure plate. The main body has a first chamber and a second chamber that are isolated from each other. The PCB board is installed in the first chamber and integrates a signal processing circuit and a magnetic induction element (such as a Hall sensor). The cover plate covers and seals the first chamber and extends towards the second chamber to form a cylindrical boss. The cup is fixed to the main body by the pressure plate and seals the second chamber. The support plate is fixed to the middle of the cup and houses the magnet inside. The spring is housed in the second chamber, with one end connected to the boss of the cover plate and the other end connected to the support plate, so that the cup, support plate, and magnet constitute an integrated floating component that can move relative to the main body under external material pressure and is reset by the spring after the pressure is removed.

[0005] Preferably, the leather cup mounting surface of the main body is inclined relative to the bottom surface of the main body.

[0006] Preferably, the bottom center of the main body extends downward to form a connector port for connecting external cables, and the PCB board is provided with a solder pad that is electrically connected to the pins inside the connector port to realize electrical lead-out.

[0007] Preferably, the main body is provided with mounting ears with round holes on both sides, which facilitates fixing the sensor as a whole to the hopper wall.

[0008] Preferably, the support plate has a positioning groove in the middle for accommodating and positioning the magnet, and a slot or pin for engaging and fixing the end of the spring.

[0009] Preferably, a rubber pad is also provided outside the connector port at the bottom of the main body to cushion vibration and enhance the seal during installation.

[0010] Secondly, the present invention also provides an alarm device, characterized in that it comprises: The grain full sensor as described in any of the preceding items, and the audible and visual alarm; The grain full sensor is electrically connected to the audible and visual alarm. When the grain full sensor detects a full state, it triggers the audible and visual alarm to issue an alarm signal.

[0011] The beneficial effects of this invention are as follows: 1. Non-contact detection with high reliability: The core detection components (magnet and Hall element) are sealed in two chambers respectively. Non-contact sensing is achieved through changes in the magnetic field. There is no mechanical wear, the life is long, and it is not affected by dust or humidity.

[0012] 2. Compact structure and good sealing performance: The dual-chamber design completely isolates the electrical parts from the mechanical moving parts, and seals them separately with a diaphragm and a cover plate, effectively preventing dust and moisture from entering and adapting to harsh working conditions.

[0013] 3. Adjustable sensitivity and precise reset: By selecting springs with different stiffness coefficients, the material pressure required to trigger the grain full signal (i.e., the squeezing force of the grain pile on the cup) can be flexibly adjusted. The spring also provides a reliable reset force, ensuring that the sensor can automatically reset after the material falls, enabling repeated detection.

[0014] 4. Easy installation and maintenance: The overall structure is modular and connected by standard connectors. The mounting ears on both sides make it easy to fix. During maintenance, only vulnerable parts such as the external rubber cups need to be replaced, without disassembling the internal circuit. Attached Figure Description

[0015] Figure 1 This is an exploded view of the overall structure of the grain full sensor according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the overall structure of the grain full sensor according to an embodiment of the present invention; The following are the labels in the diagram: 1-Main body base, 101-First chamber, 102-Second chamber, 103-Connector port, 104-Mounting ear; 2-PCB board; 3-Cover plate, 301-Cylindrical boss; 4-Spring; 5-Support plate, 501-Positioning groove, 502-Card slot; 6-Magnet; 7-Leather cup; 8-Pressure plate; 9-Rubber pad. Detailed Implementation

[0016] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0017] Firstly, such as Figure 1 and Figure 2 As shown, the present invention provides a grain full sensor, the main body (1) of which is usually made of engineering plastic, and the interior is divided into a first chamber (101) and a second chamber (102) arranged vertically by a partition. A connector port (103) extending downward is provided at the center of the bottom of the main body (1), and a pin for connecting an external cable is pre-embedded in the port. Mounting ears (104) with round holes are provided on both sides of the main body (1) for bolt fixing.

[0018] The PCB board (2) is installed in the first chamber (101), and the pads on it are soldered to one end of the pin to achieve electrical connection. The cover plate (3) covers and seals the first chamber (101) by ultrasonic welding or adhesive bonding, and its center protrudes into the second chamber (102) to form a cylindrical boss (301).

[0019] The leather cup (7) is made of a flexible, bowl-shaped sealing membrane, and is made of an aging-resistant and oil-resistant elastic material (such as silicone rubber, fluororubber, etc.). Its edge is fixed to the main body seat (1) by a ring-shaped pressure plate (8) with screws or buckles, thereby sealing the lower opening of the second chamber (102).

[0020] The support plate (5) is a rigid component (such as plastic or metal sheet) fixed to the inner side of the middle of the cup (7). On the one hand, it makes the cup more evenly stressed, and on the other hand, it provides a mounting base for the magnet 6 and the spring 4. The center of the support plate is provided with a positioning groove (501) for embedding the magnet (6), and the upper part is provided with a slot (502) for engaging one end of the spring (4). The other end of the spring (4) is fitted or engaged in the cylindrical boss (301) of the cover plate (3). Thus, the cup (7), the support plate (5), and the magnet (6) form a movable assembly suspended in the second chamber (102) under the preload of the spring (4). The spring (4) provides the only elastic force source for the reset of the movable assembly.

[0021] The cup mounting surface of the main body (1) is inclined relative to the bottom surface of the main body, and there is an acute angle between the cup mounting surface and the bottom surface of the main body. The inclined mounting surface can more effectively receive the lateral pressure of the material, thereby improving the sensitivity and detection accuracy of the sensor.

[0022] A rubber pad (9) is fitted over the connector port (103) to provide cushioning and auxiliary sealing during installation.

[0023] The sensor is installed at a preset full position on the inner wall of the silo. When the material (such as grain) has not touched the cup (7), the magnet (6) is in the initial position away from the PCB board (2) under the action of the spring (4), and the magnetic field sensed by the Hall element is weak, outputting a "not full" signal. When the material accumulates to the full height and touches the cup (7), the material exerts pressure on the cup (7), pushing the support plate (5) and the magnet (6) to move upward against the elastic force of the spring (4). The magnet (6) approaches the Hall element on the PCB board (2), the magnetic field is enhanced, the state of the Hall element flips, the circuit on the PCB board (2) processes this change and outputs a "full" signal. When the material is transported away, the material level drops, the pressure on the cup (7) disappears, the spring (4) drives the entire moving component to reset, and the sensor returns to the "not full" state.

[0024] Secondly, the present invention also provides an alarm device. This device includes the grain full sensor described in the first aspect, and an audible and visual alarm.

[0025] The grain full sensor is electrically connected to the power and signal input terminals of the audible and visual alarm via a cable through its connector port 103. When the grain full sensor detects a full state (i.e., the Hall element output state flips), it outputs a trigger signal (such as a switching signal). This signal is transmitted to the control circuit of the audible and visual alarm, which then drives the internal speaker (or buzzer) to emit a continuous or intermittent warning sound, while simultaneously driving the LED light or warning light to flash, creating a strong alarm effect that integrates sound and light, promptly reminding the operator that "the grain bin is full, please unload the grain."

[0026] It is understandable that the alarm device can also be linked with the grain silo's feeding control system to automatically stop the conveying equipment when the silo is full.

[0027] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A grain full sensor, characterized in that, include: The main body (1) has a first chamber (101) and a second chamber (102) that are isolated from each other. A PCB board (2) is installed in the first chamber (101) and has a magnetic induction element integrated thereon; The cover plate (3) is fixed inside the main body (1) and seals the first chamber (101). The cover plate (3) has a boss (301) on the side facing the second chamber (102). The leather cup (7) has its edge fixed to the main body seat (1) by a pressure plate (8) and seals the second chamber (102); The support plate (5) is fixed to the inner middle of the leather cup (7); A magnet (6) is fixedly installed inside the support plate (5) and is correspondingly installed with the magnetic induction element on the PCB board (2); A spring (4) is disposed in the second chamber (102), and its two ends are respectively connected to the boss (301) of the cover plate (3) and the support plate (5); The leather cup (7), the support plate (5) and the magnet (6) constitute a movable component that can move relative to the main body (1) under the action of external force and is provided with a restoring force by the spring (4).

2. The grain full sensor according to claim 1, characterized in that, The leather cup mounting surface of the main body (1) is inclined relative to the bottom surface of the main body.

3. The grain full sensor according to claim 1, characterized in that, The main body (1) extends downward from the center of the bottom to form a connector port (103), and the connector port (103) is provided with pins that are electrically connected to the PCB board (2).

4. The grain full sensor according to claim 3, characterized in that, The PCB board (2) is provided with a pad connected to one end of the pin; the bottom of the first chamber (101) of the main body (1) is provided with a positioning hole for the pin to pass through.

5. The grain full sensor according to claim 1, characterized in that, The main body (1) is provided with mounting ears (104) with mounting holes on both sides.

6. The grain full sensor according to claim 1, characterized in that, The support plate (5) has a positioning groove (501) in the middle for accommodating and fixing the magnet (6).

7. The grain full sensor according to claim 1 or 6, characterized in that, The support plate (5) is also provided with a snap-fit ​​structure (502) for connecting and fixing the end of the spring (4).

8. The grain full sensor according to claim 3, characterized in that, It also includes a rubber pad (9), which is fitted around the connector port (103) at the bottom of the main body (1).

9. The grain full sensor according to claim 1, characterized in that, The magnetic sensing element is a Hall element, and the magnet (6) and the Hall element constitute a non-contact inductive switch.

10. An alarm device, characterized in that, include: The grain full sensor as described in any one of claims 1-9, and the audible and visual alarm; The grain full sensor is electrically connected to the audible and visual alarm. When the grain full sensor detects a full state, it triggers the audible and visual alarm to issue an alarm signal.

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