阅读说明：本技术 一种低盲区超声波物位传感器 (Low-blind-area ultrasonic material level sensor ) 是由 董志伟 于 2021-02-09 设计创作，主要内容包括：本发明提供一种低盲区超声波物位传感器,包括壳体和两个超声波振子,其中一个所述超声波振子用于发射超声波,另一个所述超声波振子用于接收超声波,两个所述超声波振子位于所述壳体内部；两个所述超声波振子分别安装于对应的振子安装座；两个所述振子安装座之间设置分隔结构；所述壳体前端设置用于安装所述传感器的安装结构。采用本发明的技术方案解决了现有的超声波物位传感器存在检测盲区,有效测量范围不能满足需要的技术问题。(The invention provides a low-blind-area ultrasonic level sensor which comprises a shell and two ultrasonic vibrators, wherein one ultrasonic vibrator is used for transmitting ultrasonic waves, the other ultrasonic vibrator is used for receiving the ultrasonic waves, and the two ultrasonic vibrators are positioned in the shell; the two ultrasonic vibrators are respectively arranged on the corresponding vibrator mounting seats; a separation structure is arranged between the two vibrator mounting seats; the front end of the shell is provided with a mounting structure for mounting the sensor. The technical scheme of the invention solves the technical problems that the existing ultrasonic level sensor has a detection blind area and the effective measurement range cannot meet the requirement.)

1. The low-blind-area ultrasonic level sensor is characterized by comprising a shell and two ultrasonic vibrators, wherein one ultrasonic vibrator is used for transmitting ultrasonic waves, the other ultrasonic vibrator is used for receiving the ultrasonic waves, and the two ultrasonic vibrators are positioned in the shell;

the two ultrasonic vibrators are respectively arranged on the corresponding vibrator mounting seats; a separation structure is arranged between the two vibrator mounting seats;

the front end of the shell is provided with a mounting structure for mounting the sensor.

2. The low blind zone ultrasonic level sensor according to claim 1, wherein the ultrasonic vibrator is a circular, ring or rectangular ultrasonic transducer.

3. The low blind zone ultrasonic level sensor of claim 1, wherein the ultrasonic transducer is a semicircular ultrasonic transducer.

4. The low blind zone ultrasonic level sensor according to claim 1, wherein a matching layer is bonded between the ultrasonic vibrator and the vibrator mounting base.

5. The low blind zone ultrasonic level sensor according to claim 1, wherein the side of the ultrasonic vibrator for receiving ultrasonic waves is provided with a metal shielding layer.

6. The low blind zone ultrasonic level sensor according to claim 1, wherein a damping material is adhered to a side or rear of the ultrasonic vibrator for emitting ultrasonic waves.

7. The low blind zone ultrasonic level sensor according to claim 1, wherein a damping material is adhered to a side or rear of the ultrasonic vibrator for receiving ultrasonic waves.

8. The low blind area ultrasonic level sensor according to claim 1, wherein the vibrator mounting seat is a bottom surface of the housing or a vibrator shell, and the vibrator mounting seat corresponding to each ultrasonic vibrator can be the bottom surface of the housing or the vibrator shell.

9. The low blind area ultrasonic level sensor according to claim 8, wherein when the ultrasonic vibrator is mounted to the vibrator housing, a rubber ring is disposed between the vibrator housing and the separation structure, and the vibrator housing is disposed in-line with the separation structure.

10. The low blind zone ultrasonic level sensor according to claim 1, wherein the transducer mounting base has different front and rear positions and a height difference in a vertical direction.

11. The low blind zone ultrasonic level sensor of claim 1, wherein the mounting structure is a mounting thread.

Technical Field

The invention relates to the field of level measurement, in particular to a low-blind-area ultrasonic level sensor.

Background

Ultrasonic level sensors are used for level measurement, i.e. for measuring the liquid or solid level in various containers, or for measuring distances.

As shown in fig. 1, the conventional ultrasonic level sensor is composed of a housing 36 and an ultrasonic transducer 37 mounted in the housing, the transducer is bonded to the housing via a matching layer 38, and a mounting screw 39 is provided at the rear of the housing. The ultrasonic transducer 37 is a single ultrasonic transducer that integrates transmission and reception, and may be a circular ultrasonic transducer or a sandwich transducer including front and rear electrodes and an ultrasonic transducer. The ultrasonic vibrator is driven by high-voltage pulse of the electronic unit to emit ultrasonic waves outwards, the ultrasonic waves are reflected by an object in the process of propagation, are received by the ultrasonic vibrator again and are converted into electric pulses, the electric unit detects the electric pulses, the propagation distance of the ultrasonic waves can be determined according to the time from the transmission of the ultrasonic waves to the reflection of the ultrasonic waves, and the ultrasonic vibrator can be used for measuring the distance and judging the position of the object according to the principle.

The existing ultrasonic level sensor is a single ultrasonic vibrator, the ultrasonic sensor cannot simultaneously distinguish reflected echoes when the ultrasonic sensor actively transmits ultrasonic waves, residual vibration with a certain time length still exists after the ultrasonic sensor actively transmits the ultrasonic waves, and the reflected echoes cannot be distinguished when the residual vibration is strong, so that the level cannot be detected within a distance from the surface of the sensor to the outside, and the distance is a blind area. Due to the existence of the blind area, and because the existing ultrasonic sensor is usually installed through the rear screw thread 33, when the ultrasonic sensor is used for measuring the liquid level or the solid level in the container, the front part of the sensor needs to go deep into the flange opening of the measured container, which is equivalent to the increase of the blind area of the probe, so that the effective measuring range of the level gauge is reduced, and the liquid level or the liquid level in the container cannot be detected when the liquid level or the solid level rises to be higher, which is not allowed in many cases and cannot meet the requirement of level measurement.

Disclosure of Invention

According to the technical problems that the existing ultrasonic level sensor has a detection blind area and the effective measurement range cannot meet the requirements, the low-blind-area ultrasonic level sensor is provided, the blind area value can be greatly reduced, the effective measurement range is increased, and the requirements of level measurement are met.

The technical means adopted by the invention are as follows:

a low-blind-area ultrasonic level sensor comprises a shell and two ultrasonic vibrators, wherein one ultrasonic vibrator is used for transmitting ultrasonic waves, the other ultrasonic vibrator is used for receiving the ultrasonic waves, and the two ultrasonic vibrators are positioned in the shell;

the two ultrasonic vibrators are respectively arranged on the corresponding vibrator mounting seats; a separation structure is arranged between the two vibrator mounting seats;

the front end of the shell is provided with a mounting structure for mounting the sensor.

Further, the ultrasonic vibrator is a circular, annular or rectangular ultrasonic transducer.

Further, the ultrasonic vibrator is a semicircular ultrasonic transducer.

Furthermore, a matching layer is bonded between the ultrasonic vibrator and the vibrator mounting seat.

Further, a metal shielding layer is arranged on the side surface of the ultrasonic vibrator for receiving ultrasonic waves.

Further, a damping material is adhered to a side or rear portion of the ultrasonic vibrator for emitting ultrasonic waves.

Further, a damping material is adhered to a side or rear portion of the ultrasonic vibrator for receiving ultrasonic waves.

Further, the vibrator mounting seat may be a bottom surface of the housing or a vibrator housing, and the vibrator mounting seat corresponding to each ultrasonic vibrator may be the bottom surface of the housing or the vibrator housing.

Further, when the ultrasonic vibrator is installed on the vibrator shell, a rubber ring is arranged between the vibrator shell and the separation structure, and the vibrator shell is embedded in the separation structure.

Furthermore, the front and back positions of the vibrator installation seat are different, and a height difference exists in the vertical direction.

Further, the mounting structure is a mounting thread.

Compared with the prior art, the invention has the following advantages:

the low-blind-area ultrasonic level sensor provided by the invention is provided with the two vibrators, because the two vibrators are not positioned on the same structure, when one vibrator emits ultrasonic waves to generate vibration, the other vibrator is slightly influenced by the vibration, and meanwhile, because the ultrasonic level sensor is installed by adopting the front-end threads, reflected echoes can be quickly or simultaneously received, so that the blind area of the sensor is very small or even zero.

For the above reasons, the present invention can be widely applied to the fields of level measurement, etc.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.

Fig. 1 is a schematic structural view of an ultrasonic level sensor in the prior art.

FIG. 2 is a schematic view of an ultrasonic level sensor according to the present invention.

FIG. 3 is a schematic structural view of an ultrasonic level sensor according to embodiment 1 of the present invention.

Fig. 4 is a schematic sectional view of a combination of one of the vibrators and a housing in embodiment 1 of the invention.

FIG. 5 is a schematic structural view of an ultrasonic level sensor according to embodiment 2 of the present invention.

FIG. 6 is a graph of transmitted and echo waveforms for a prior art ultrasonic level sensor.

FIG. 7 is a diagram of waveforms of transmitted waves and echoes of the ultrasonic level sensor according to embodiment 1 of the present invention.

FIG. 8 is a diagram of waveforms of transmitted waves and echoes of the ultrasonic level sensor according to embodiment 2 of the present invention.

Fig. 9 is a schematic structural view of the partition structure according to the present invention.

In the figure: 1. 19, 31, 36: a housing; 3. 9, 11, 18, 23, 30, 37: an ultrasonic vibrator; 4. 8, 17, 24, 29, 33, 38: a matching layer; 22. 34: a metal shielding layer; 5. 7, 16, 25 and 28 vibrator mounting seats; 13. a vibrator housing; 12. a rubber ring; 6. 15, 27, 39: installing threads; 2. 14, 26: a partition structure; 20. 32: an electronic unit; 10. 21: a housing upper cover; 35. a damping material.

Detailed Description

It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.

The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. Any specific values in all examples shown and discussed herein are to be construed as exemplary only and not as limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.

In the description of the present invention, it is to be understood that the orientation or positional relationship indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the orientation or positional relationship shown in the drawings, and are used for convenience of description and simplicity of description only, and in the absence of any contrary indication, these directional terms are not intended to indicate and imply that the device or element so referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore should not be considered as limiting the scope of the present invention: the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.

Spatially relative terms, such as "above … …," "above … …," "above … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of the present invention should not be construed as being limited.

Example 1

As shown in fig. 2, the present invention provides a low blind area ultrasonic level sensor, which comprises a housing 1 and two ultrasonic vibrators 3, 9, wherein one ultrasonic vibrator 3 is used for transmitting ultrasonic waves, the other ultrasonic vibrator 9 is used for receiving ultrasonic waves, and the two ultrasonic vibrators 3, 9 are located inside the housing 1;

the two ultrasonic vibrators 3 and 9 are respectively arranged on the corresponding vibrator mounting seats 5 and 7; a separation structure 2 is arranged between the two vibrator mounting seats 5 and 7;

the front end of the shell 1 is provided with a mounting structure for mounting the sensor.

When two ultrasonic vibrators are installed on two vibrator installation bases respectively, two vibrator installation bases can be better separated by the separation structure, the vibration influence between the two installation bases is reduced, because the two ultrasonic vibrators are installed on different structures, the influence of the vibration generated when the ultrasonic vibrators transmit sound waves on the ultrasonic vibrators is small, the residual vibration received by the ultrasonic vibrators is small, the echo can be received quickly, and the detection blind area of the sensor is small.

The existing ultrasonic level sensor is usually required to be installed in a container for detection, but when the material level or the liquid level in the container rises to be higher, the detection cannot be carried out due to the existence of a blind area.

Further, the ultrasonic vibrator is a circular, annular or rectangular ultrasonic transducer.

Further, matching layers 4 and 8 are bonded between the ultrasonic vibrators 3 and 9 and the vibrator mounting bases 5 and 7, so that acoustic wave signals can be effectively transmitted and received.

Further, a metal shielding layer is arranged on the side surface of the ultrasonic vibrator for receiving ultrasonic waves.

Further, a damping material is adhered to a side or rear portion of the ultrasonic vibrator for emitting ultrasonic waves.

Further, a damping material is adhered to a side or rear portion of the ultrasonic vibrator for receiving ultrasonic waves.

Further, the vibrator mounting seat may be a bottom surface of the housing or a vibrator housing, and the vibrator mounting seat corresponding to each ultrasonic vibrator may be the bottom surface of the housing or the vibrator housing.

Preferably, as shown in fig. 2, the vibrator mounting seats 5 and 7 are bottom surfaces of the housing 1, the ultrasonic vibrators 3 and 9 are respectively bonded to the vibrator mounting seats 5 and 7 through the matching layers 4 and 8, the two vibrator mounting seats 5 and 7 are not in the same horizontal plane, and the partition structure 2 between the two vibrator mounting seats 5 and 7 is a vertical baffle structure;

further, as shown in fig. 9(a) - (e), the partition structure 2 may be provided as a convex structure (a, b), a concave structure (c), a vertical baffle structure (d) or an inverted T-shaped structure (e); as shown in fig. 9(a), (c) and (e), the mounting surfaces of the two ultrasonic vibrators 3, 9 may be located in the same horizontal plane, that is, the two vibrator mounting seats 5, 7 are located in the same horizontal plane, or the mounting surfaces of the two ultrasonic vibrators 3, 9 are not located in the same horizontal plane, that is, the two vibrator mounting seats 5, 7 are not located in the same horizontal plane, and preferably, as shown in fig. 9(b), (d), a height difference may be provided in the vertical direction.

Furthermore, the mounting structure is the mounting thread 6, and the sensor mounted outside the container can increase the propagation stroke of echo signals, reduce the detection blind area, and improve the close-range inspection range.

In the ultrasonic level sensor of the present embodiment, because the two vibrators are not located in the same structure, when one vibrator emits ultrasonic waves to generate vibration, the other vibrator is affected by the vibration very little, and meanwhile, because the ultrasonic level sensor is installed outside the container through the installation thread 6, the ultrasonic level sensor can receive reflected echoes very fast or simultaneously, so that the dead zone of the sensor is very small or even zero.

Preferably, as shown in fig. 9(e), the vibrator mounting seats 5 and 7 corresponding to the two ultrasonic vibrators 3 and 9 are both vibrator housings, the ultrasonic vibrators 3 and 9 are respectively bonded in the vibrator housings through the matching layers 4 and 8, and rubber rings are arranged between the vibrator housings 5 and 7 and the separation structure 2; the partition structure 2 between the transducer mounting seats 5 and 7 may be an inverted T-shaped structure, and the mounting surfaces of the two ultrasonic transducers 3 and 9 may be located in the same horizontal plane, or the mounting surfaces of the two ultrasonic transducers 3 and 9 may not be located in the same horizontal plane.

Preferably, as shown in fig. 3, the ultrasonic vibrators 11 and 18 are circular ultrasonic transducers, the diameter of each ultrasonic transducer is 20mm, the thickness of each ultrasonic transducer is 6mm, the ultrasonic vibrator 18 is used for transmitting ultrasonic waves, the ultrasonic vibrator 11 is used for receiving echoes, and when the housing 19 is vertically placed, the ultrasonic vibrator 18 and the ultrasonic vibrator 11 are distributed in a left-right manner.

Further, the housing 19 is cylindrical and has a diameter of 60 mm.

Further, an electronic unit 20 electrically connected to the ultrasonic vibrator is disposed in the housing 19, and is configured to control the ultrasonic vibrator to transmit ultrasonic waves and receive echo signals.

Further, the housing 19 is provided with a mounting thread 15 at one end for mounting the sensor in use, and a housing upper cover 10 at the other end, the housing upper cover 10 being provided with a cable lead-in device.

Furthermore, the transducer mounting base 16 corresponding to the ultrasonic transducer 18 is the bottom surface of the housing 19, and the ultrasonic transducer 18 is bonded to the bottom surface of the housing 19 through the matching layer 17;

the vibrator mounting seat corresponding to the ultrasonic vibrator 11 is the vibrator shell 13, the separation structure 14 arranged between the vibrator mounting seat 16 and the vibrator shell 13 is a cylindrical structure arranged on the bottom surface of the shell 19, and the vibrator shell 13 is embedded in the separation structure 14;

as shown in fig. 4, the ultrasonic vibrator 11 is bonded in the vibrator housing 13 through the matching layer 33, and a rubber ring 12 is disposed between the vibrator housing 13 and the separation structure 14;

the metal shielding layer 34 is arranged on the side surface of the ultrasonic vibrator 11, and the metal shielding layer 34 is positioned between the ultrasonic vibrator 11 and the vibrator shell 13;

the damping material 35 is adhered to the side surface or the rear part of the ultrasonic vibrator 11, and the damping material may be soft polyurethane pouring sealant.

Further, the rear space of the ultrasonic vibrators 11, 18 should be arranged with a sound absorbing material.

The waveforms of the transmitted wave and the echo when the sensor is used for near-distance detection are as shown in fig. 7, the transmitted wave and the residual vibration received by the receiving vibrator are narrow, about 200us, and meanwhile, because the two ultrasonic vibrators are positioned at different positions from top to bottom, when a measured object approaches the sensor, the narrow transmitted wave and the narrow residual vibration are allowed to exist, the echo and the transmitted wave are not overlapped and can be normally detected, and meanwhile, because the ultrasonic level sensor is installed by adopting front-end threads, the blind area of the ultrasonic level sensor can reach 2cm or even zero. The close-range measurement waveform of a conventional ultrasonic level sensor for comparison is shown in FIG. 6, which has a nominal dead zone of 25cm and a narrow transmit wave and residual vibration of about 1400 us.

Example 2

As shown in fig. 5, the present embodiment is different from embodiment 1 in that the shape of the ultrasonic vibrator is different, and in order to fully utilize the internal space of the housing 31, the ultrasonic vibrators 23, 30 in the present embodiment are semicircular piezoelectric ceramic plates, and such a shape can make the vibrators have a larger surface area, the transmitting power of the vibrators can be larger, and the receiving sensitivity is higher; the ultrasonic vibrators 23 and 30 are semicircular, the radius is 18mm, and the thickness is 4 mm; the ultrasonic transducer 30 is used for emitting ultrasonic waves, and the ultrasonic transducer 23 is used for receiving echoes.

Further, the transducer mounting seat 28 corresponding to the ultrasonic transducer 30 is a bottom surface of the case 31, and the ultrasonic transducer 30 is bonded to the bottom surface of the case 31 through the matching layer 29;

the ultrasonic vibrator 23 corresponds to the vibrator mounting seat 25 and is matched with the vibrator mounting seat 25 in shape, the separation structure 26 arranged between the vibrator mounting seat 28 and the vibrator mounting seat 25 is a semi-cylindrical structure arranged on the bottom surface of the shell 31, and the vibrator mounting seat 25 is embedded in the separation structure 26;

the ultrasonic vibrator 23 is bonded in the vibrator mounting seat 25 through the matching layer 24;

the metal shielding layer 22 is arranged on the side surface of the ultrasonic vibrator 23, and the metal shielding layer 22 is positioned between the ultrasonic vibrator 23 and the upper part of the separation structure 26; the damping material is adhered to the side surface or the rear part of the ultrasonic vibrator 23; an electronic unit 32 is arranged in the shell 31; the housing 31 has a mounting thread 27 at one end and a housing upper cover 21 at the other end.

The waveforms of the transmitted wave and the echo in the short-distance detection of embodiment 2 are as shown in fig. 8, and the transmitted wave and the residual vibration received by the receiving oscillator are also narrow, about 350 us; meanwhile, the transmitting vibrator and the receiving vibrator are arranged at different positions from top to bottom, so that when a measured object approaches the sensor, narrow transmitting waves and residual vibration are allowed to exist, echo waves and the transmitting waves are not overlapped, normal detection can be realized, and meanwhile, the blind area of the ultrasonic level sensor can reach 5cm due to the fact that the ultrasonic level sensor is installed through front-end threads. The close-range measurement waveform of a conventional ultrasonic level sensor for comparison is shown in FIG. 6, which has a nominal dead zone of 25cm and a narrow transmit wave and residual vibration of about 1400 us.

Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.