CN111895922A - Device, system and method for monitoring silo stacking height - Google Patents

Device, system and method for monitoring silo stacking height Download PDF

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Publication number
CN111895922A
CN111895922A CN202010607307.3A CN202010607307A CN111895922A CN 111895922 A CN111895922 A CN 111895922A CN 202010607307 A CN202010607307 A CN 202010607307A CN 111895922 A CN111895922 A CN 111895922A
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China
Prior art keywords
monitoring
light
silo
height
laser detection
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Chinese (zh)
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张石
刘志文
李亚锋
鲁佶
陈俊麟
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Information Research Institute Of Emergency Management Department
Wuhan Kyle Optics Technology Co ltd
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Information Research Institute Of Emergency Management Department
Wuhan Kyle Optics Technology Co ltd
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Priority to CN202010607307.3A priority Critical patent/CN111895922A/en
Publication of CN111895922A publication Critical patent/CN111895922A/en
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/02Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0608Height gauges

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  • General Physics & Mathematics (AREA)
  • Measurement Of Levels Of Liquids Or Fluent Solid Materials (AREA)

Abstract

The invention relates to the field of automatic monitoring, in particular to a device, a system and a method for monitoring silo stacking height. The method mainly comprises the following steps: at least one data processing module and at least one group of monitoring modules; each group of monitoring modules comprises at least one laser detection assembly and a shell, the laser detection assembly is hermetically sealed in the shell, an electrical interface of the laser detection assembly is used as an external electrical interface of the monitoring module, the shell comprises a light-transmitting window and a valve, the light-transmitting window corresponds to a monitoring light outlet and a reflected light receiving opening of the laser detection assembly in position, the valve is positioned outside the light-transmitting window, the light-transmitting window is completely covered by the valve when the valve is closed, and the light-transmitting window is exposed to the outside when the valve is opened; the data processing module is coupled with a respective port of the external electrical interface of each set of monitoring modules. The invention can conveniently and accurately acquire the heights of different positions of the top end of the stacking material through a plurality of laser ranging modules, thereby monitoring the whole height of the stacking material.

Description

Device, system and method for monitoring silo stacking height
[ technical field ] A method for producing a semiconductor device
The invention relates to the field of automatic monitoring, in particular to a device, a system and a method for monitoring silo stacking height.
[ background of the invention ]
The closed silo is adopted to store the materials, so that the secondary pollution to the surrounding environment in the storage process can be effectively reduced, the material waste in the turnover link can be reduced, and the problems of material quality reduction, large occupied area, difficult management and the like in the open-air stacking process are solved. However, when the materials are stored in the closed silo, potential safety hazards may occur if the stacking height is too high. In order to realize safe storage and production of materials, the silo stacking height needs to be monitored in real time, and the stored information is fed back to a control system.
At present, the main silo stockpiling monitoring technical methods comprise a capacitance type measuring method, a weight type measuring method, a nuclear radiation type measuring method, an ultrasonic type measuring method, an electrode type measuring method and the like. The capacitance type measuring method is simple in structure, but requires stable dielectric constant of materials, electrodes are easy to adhere to the materials and are damaged, and the capacitance type measuring method is only suitable for silos with small water content, stable chemical properties and small size. The heavy hammer type measurement method requires that the surface of the material must be contacted with a heavy hammer in the measurement process, and has poor reliability, high failure rate and low automation degree. The nuclear radiation type measurement method has high protection requirement due to the existence of radiation, and is expensive when continuously measuring. The ultrasonic measurement method has the advantages of large measurement blind area, limited measurement depth, easy influence of dust, easy influence of factors such as temperature, sound pressure and wind power and poor reliability. The electrode type measurement method is easy to cause the instability of the system due to the complex material components and inconsistent resistivity.
In view of this, how to overcome the defects existing in the prior art and solve the defects of poor reliability and the like existing in the existing various measurement methods is a problem to be solved in the technical field.
[ summary of the invention ]
Aiming at the defects or improvement requirements of the prior art, the invention solves the problems of higher requirements on material characteristics, poor measurement stability and the like in the existing measurement method.
The embodiment of the invention adopts the following technical scheme:
in a first aspect, the present invention provides a device for monitoring the silo stacking height, which specifically comprises: comprises at least one data processing module 10 and at least one group of monitoring modules 20; each group of monitoring modules 20 comprises at least one laser detection assembly 21 and a shell 22, the laser detection assembly 21 is hermetically sealed in the shell 22, an electrical interface of the laser detection assembly 21 is used as an external electrical interface of the monitoring module 20, the shell 22 comprises a light-transmitting window 22-1 and a valve 22-2, the light-transmitting window 22-1 corresponds to a monitoring light outlet and a reflected light receiving port of the laser detection assembly 21 in position, the valve 22-2 is positioned outside the light-transmitting window 22-1, the light-transmitting window 22-1 is completely covered by the valve 22-2 when the valve 22-2 is closed, and the light-transmitting window 22-1 is exposed to the outside when the valve 22-2 is opened; the data processing module 10 is coupled to a respective port of the external electrical interface of each set of monitoring modules 20.
Preferably, the device further comprises a light source 30 and a light splitter 40; the optical splitter 40 comprises an input port and at least one output port, wherein the number of the output ports is not less than the number of the laser detection assemblies 21; the emergent light of the light source 30 is coupled with the input port optical path of the optical splitter 40; the laser detection assembly 21 comprises a light emitting component 21-1 and a light receiving component 21-2, wherein an input port of the light emitting component 21-1 of each laser detection assembly 21 is optically coupled with an output port of the optical splitter 40 to serve as an input port of the optical path of the laser detection assembly 21, the light receiving component 21-2 is optically coupled with a reflected optical path of light emitted by the light emitting component 21-1, and an electrical interface of the light receiving component 21-2 serves as an electrical interface of the laser detection assembly 21.
Preferably, the laser detection assembly 21 further comprises a cleaning member 22-3, wherein the cleaning member 22-3 is movably fixed outside the light-transmissive window 22-1 and moves in a translational manner close to the light-transmissive window 22-1 so as to clean the outside of the light-transmissive window 22-1.
In a second aspect, the present invention also provides a system for monitoring silo windrow height, comprising: the monitoring device 1, the monitoring control device 2 and the silo 3 are designed according to the device for monitoring the silo stockpiling height provided by the first aspect; the monitoring module 20 in the monitoring device 1 is arranged at the top in the silo 3, and the light-transmitting window 22-1 of the monitoring module 20 faces the top surface of the stockpile in the silo 3; the monitoring control device 2 interacts with the data processing module 10 in the monitoring device 1 to perform data signal and control signal interaction, so that the stockpiling height of the silo 3 can be analyzed and monitored through the data acquired by the monitoring device 1.
Preferably, the shape of the distribution region of the monitoring modules 20 is the same as the shape of the top of the silo 3, and the distance between every two monitoring modules 20 located within the preset central region is smaller than the distance between every two monitoring modules 20 located outside the preset central region.
Preferably, the connection between the monitoring device 1 and the monitoring control device 2 is an explosion-proof cable.
In a third aspect, the present invention also provides a method of monitoring silo windrow height, comprising: the system for silo stockpiling height monitoring proposed according to the second aspect deploys a monitoring module 20 in the silo 3; the monitoring module 20 sends a monitoring optical signal to the top of the stacking material; the monitoring module 20 acquires a reflected light signal obtained by reflecting the monitoring light signal by the top of the stockpile; the data processing module 10 obtains the height data of the top of the piled material according to the reflected light signal data of all the monitoring modules 20; the monitoring control device 2 judges the state of the top height of the pile according to the top height data of the pile obtained by the data processing module 10.
Preferably, obtaining the windrow top height data comprises: and fitting the shape of the top of the piled material according to the horizontal positions of the different monitoring modules 20 and the acquired reflected light signal data to acquire three-dimensional data of the shape of the top of the piled material.
Preferably, the data processing module 10 acquires the reflected light signal data of all the monitoring modules 20, including: the data processing module 10 calculates the stacking height of the corresponding position of each monitoring module 20 according to the time difference between the emitting time of the monitoring light and the returning time of the reflected light of each monitoring module 20.
Preferably, the method further comprises the following steps: when the monitoring module 20 is required to send a monitoring optical signal to the top of the stockpile and the monitoring module 20 is required to acquire a reflected optical signal, the monitoring control device 2 opens a valve 22-2 on the monitoring module 20.
Compared with the prior art, the embodiment of the invention has the beneficial effects that: the utility model provides a device of monitoring of silo windrow height, the height of the convenient accurate acquisition windrow top different positions of through a plurality of laser rangefinder modules to monitor the whole height of windrow. Still through carrying out airtight encapsulation to laser rangefinder module to set up valve and cleaning brush in airtight encapsulated light-transmitting window department, reduce the influence of external environment to the monitoring accuracy.
Furthermore, the invention provides a system for monitoring the height of the silo stockpile, which combines the device for monitoring the height of the silo stockpile with a main control system, arranges the distance measuring module at a proper position in the silo, and more accurately fits the three-dimensional shape of the surface of the stockpile to obtain more accurate monitoring data.
[ description of the drawings ]
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required to be used in the embodiments of the present invention will be briefly described below. It is obvious that the drawings described below are only some embodiments of the invention, and that for a person skilled in the art, other drawings can be derived from them without inventive effort.
Fig. 1 is a schematic structural diagram of an apparatus for monitoring the height of a silo dump according to an embodiment of the present invention;
fig. 2 is a schematic system structure diagram of a data processing module in a silo stockpiling height monitoring device according to an embodiment of the present invention;
FIG. 3 is a schematic structural view of another apparatus for monitoring the silo material level according to an embodiment of the present invention;
FIG. 4 is a schematic structural view of another apparatus for monitoring the silo material level according to an embodiment of the present invention;
FIG. 5 is a schematic structural view of another apparatus for monitoring the silo windrow height according to an embodiment of the present invention;
FIG. 6 is a schematic structural view of another apparatus for monitoring the silo windrow height according to an embodiment of the present invention;
fig. 7 is a schematic structural diagram of a system for monitoring the height of a silo dump according to an embodiment of the present invention;
fig. 8 is a schematic diagram illustrating a manner of monitoring modules in a silo stockpiling height monitoring system according to an embodiment of the present invention;
fig. 9 is a schematic diagram of another monitoring module in a silo stockpiling height monitoring system according to an embodiment of the present invention;
figure 10 is a flow chart of a method of monitoring silo windrow height according to an embodiment of the present invention;
wherein the reference numbers are as follows:
1: a monitoring device; 2: monitoring a control device; 3: a silo;
10: data processing module, 11: processor, 12: a memory; 20: monitoring module, 21: laser detection assembly, 21-1: light emitting part, 21-2 light receiving part, 22: housing, 22-1 light transmissive window, 22-2: valve, 22-3: cleaning member, 22-4: an electric motor; 30: a light source; 40: a light splitter.
[ detailed description ] embodiments
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The present invention is a system structure of a specific function system, so the functional logic relationship of each structural module is mainly explained in the specific embodiment, and the specific software and hardware implementation is not limited.
In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other. The invention will be described in detail below with reference to the figures and examples.
Example 1:
when the silo is stored, in order to automatically monitor the stock and the change condition of the materials in the silo in real time, an automatic sensing device is needed to measure the height of the materials. Because the physical and chemical characteristics of the materials such as water content, components, shape, conductivity coefficient and the like are different, some common automatic sensing devices cannot accurately and stably measure the height of the materials. The embodiment provides a stacking height measuring device for silo storage, which can automatically, quickly, accurately and stably obtain the stacking heights of different materials in a silo.
The following describes a specific structure of the device for monitoring the silo material stacking height provided by the present embodiment with reference to fig. 1:
the apparatus for silo windage height monitoring comprises at least one data processing module 10 and at least one set of monitoring modules 20. The monitoring module 20 obtains the distance between the top surface of the stockpile at different positions in the silo and the laser detection assembly 21 through the laser detection assembly 21, and calculates the height of the top surface of the stockpile according to the installation height of the laser detection assembly 21 and the distance between the top surface of the stockpile and the laser detection assembly 21.
Due to the fluidity of the heap, the top of the heap may undulate into the silo. Thus, the silo-stockpile height monitoring apparatus provided in this embodiment uses a plurality of sets of monitoring modules 20, indicated in FIG. 1 as 20-1, 20-2 … … 20-n. Each group of monitoring modules 20 comprises a laser detection assembly 21 capable of detecting, the heights of multiple positions at the top of the stacking material can be obtained, and monitoring data deviation caused when only a convex position or only a concave position is detected under the condition that only one group of monitoring modules 20 is avoided. Furthermore, each group of monitoring modules 20 may include a plurality of laser detection assemblies 21, data of the plurality of laser detection assemblies 21 is used as measurement data of the monitoring module 20, the point measurement is expanded to a small-range planar measurement, data errors caused by single-point measurement of each laser detection assembly are further avoided, and the monitoring precision is improved.
In order to process the measurement data of the monitoring module 20, the device for monitoring the silo material stacking height provided by the embodiment further comprises a data processing module 10. Fig. 2 is a schematic diagram of the architecture of a data processing module 10 used in the embodiment of the present invention. The data processing module 10 comprises one or more processors 11 and a memory 12. In fig. 2, one processor 11 is taken as an example. The processor 11 and the memory 12 may be connected by a bus or other means, such as the bus connection in fig. 2. The memory 12 is a non-volatile readable storage medium, and can be used to store non-volatile software programs, non-volatile computer executable programs, and data, such as the measurement data acquired by the monitoring module 20 in the embodiment, and a calculation program of the measurement data. Processor 11 processes the data acquired by monitoring module 20 by executing non-volatile software programs, instructions, and modules stored in memory 12. The memory 12 may include high speed random access memory and may also include non-volatile memory, such as at least one magnetic disk storage device, flash memory device, or other non-volatile solid state storage device. In some embodiments, the memory 12 may optionally include memory located remotely from the processor 11, and these remote memories may be connected to the processor 11 via a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
In the specific use scenario of this embodiment, under the condition that the top surface of the pile is relatively flat or the requirement for monitoring accuracy of the height of the pile is not high, the average value of data of the plurality of laser detection assemblies 21 can be used as the height of the top surface of the pile, and the height of the top surface of the pile can be simply and conveniently calculated. Under the condition that the fluctuation of the top surface of the stacking material is large or the requirement on the monitoring precision of the height of the stacking material is high, three-dimensional fitting can be carried out on the appearance of the top of the stacking material according to the horizontal position of each laser detection assembly 21 and the obtained distance data, the shape of the top of the stacking material is completely reconstructed, and therefore more accurate monitoring is carried out on the height of the stacking material.
Further, in a specific implementation scenario of the embodiment, one or more data processing modules 10 may be provided according to differences in installation space, data processing complexity, and the like. If complex processing such as three-dimensional fitting needs to be performed on the data in the monitoring module 20, the data processing module 10 needs to use a computing device with a relatively strong function, but this type of device generally has a relatively large volume and a relatively high cost, but can process all the data of the monitoring module 20. In this scenario, only one data processing module 10 may be used, and the data primarily processed by each monitoring module 20 is sent to the same data processing module 10 for unified processing, and for convenience of management, the data processing module 10 may also be integrated with the monitoring control device 2 of the silo material stacking height monitoring system. If only the monitoring data of each monitoring module 20 needs to be simply acquired, the data processing module 10 can use a computing device with weaker computing power, the device generally has a smaller size and lower cost, the data processing module 10 can be independently configured for each monitoring module 20, the time for signal return is independently calculated for each monitoring module 20, then the distances corresponding to different monitoring modules 20 are obtained, then the distance values are sent to the monitoring control device 2 of the system for monitoring the stacking height, the data calculation process of each monitoring module 20 is independent of the data calculation process of all monitoring modules, and the overall calculation efficiency is improved. Different types and numbers of the data processing modules 10 are set according to different scenes, so that the processing efficiency can be improved and the equipment cost can be reduced under the condition of meeting the monitoring requirement. The interface between the data processing module 10 and the monitoring module 20 may be a level signal interface, a general data interface, or other general IO interfaces according to the difference of the data to be processed by the data processing module 10 and the difference of the device physical interfaces.
Due to different physical and chemical properties of the stockpile, various defects exist in the conventional capacitance measuring method, weight measuring method, nuclear radiation measuring method, ultrasonic measuring method, electrode measuring method and the like, so that the measuring reliability is poor, and the monitoring data is unstable. In the device for monitoring the height of the silo stockpile provided by this embodiment, the monitoring module 20 uses the laser detection assemblies 21 as a measuring device, and by emitting laser to the surface of the top of the stockpile and acquiring reflected light, calculates the relative distance between the laser detection assemblies 21 and the top surface of the stockpile according to the time difference between the time when each laser detection assembly 21 monitors the emission of the light and the time when the reflected light returns, and then calculates the height of the top surface of the stockpile according to the installation height of the laser detection assemblies 21, so as to monitor the height of the stockpile. The method has the advantages that the laser ranging is used as a stacking height data acquisition mode, only the simple characteristic that the stacking is opaque and can reflect laser is utilized, the characteristics are irrelevant to other physicochemical characteristics and environmental factors of the stacking, the method can be suitable for various application occasions with different physicochemical characteristics, and measurement data can be accurately and stably acquired; meanwhile, the laser ranging mode does not need the direct contact of the testing equipment and the stacking material, so that the abnormal testing data or equipment damage caused by the adhesion of the stacking material and the testing equipment is avoided, and the working stability of the monitoring device is improved. In a specific implementation scenario, the laser detection assembly 21 may use various existing laser range finders to directly obtain the distance between the laser detection assembly 21 and the top surface of the stacking material, and the data processing module 10 directly calculates the height of the top surface of the stacking material according to the obtained distance value; it is also possible to use a laser transmitter including a collimating system as the light emitting part 21-1, use a photo sensor capable of acquiring the arrival time of the reflected light as the light receiving part 21-2, perform only the transmission of the monitoring light and the reception of the reflected light, and the data processing module 10 calculates the distance between the laser detecting assembly 21 and the pile top surface by monitoring the time difference between the transmission and reception of the light, and further calculates the height of the pile top surface.
In some usage scenarios of this embodiment, coal, ore or grain and the like are stored in the silo and may generate dust, and the dust is liable to interfere with and damage the optical device and the electronic device in the laser detection assembly 21, so that the measurement result is deviated, which affects the monitoring accuracy, or causes equipment failure and affects the stability of the device. In order to avoid the influence of external environments such as dust on the laser detection assemblies 21, the laser detection assemblies 21 in each group of monitoring modules 20 are externally provided with a casing 22, and the laser detection assemblies 21 are hermetically sealed in the casing 22. In a preferred embodiment of the present invention, in order to ensure the airtight effect of the housing 22, the sealing performance of the housing 22 needs to meet the standards above IP67, and can meet the requirements of water resistance, dust resistance, and the like, and ensure the stable operation of each precision element inside the laser detection assembly 21.
Because the laser detection assembly 21 needs to perform data interaction with the data processing module 10 and needs to acquire a power supply and a control signal from the outside, after the laser detection assembly 21 is packaged by the shell 22, the wiring of an electrical interface needs to be led out to the outside under the condition of ensuring the air tightness of the shell 22; in a scenario where a plurality of monitoring modules 20 share a light source, it is also necessary to lead out the optical path system to the outside. In a specific implementation scenario, a hole may be simply formed in the housing 22, the connection wire to be led out may be pulled out, and a gap between the hole and the connection wire may be sealed by using a sealant, a gasket, or the like. And a flange opening can be arranged at the opening, and the connection wire is led out through the flange opening. In a scene with a high sealing requirement, a switching port may be further disposed on the housing 22, a port of the laser detection component 21 is connected to an inner side of a corresponding switching port on the housing 22, and connection wires of external devices such as the external power supply, the light source 30, the data processing module 10, and the like are connected to an outer side of the corresponding switching port, so that communication between the internal connection and the external connection is realized through the switching port. The laser detection assembly 21 can be connected with an external circuit under the condition of ensuring air tightness by the above modes, and a proper scheme can be selected for implementation according to the cost, the processing complexity, the air tightness requirement and the like in practical use.
Because the laser detection assembly 21 needs to emit laser to the outside and obtain reflected light for measurement, a light-transmitting window 22-1 is formed in the shell 22, and the light-transmitting window 22-1 corresponds to the monitoring light outlet and the reflected light receiving opening of the laser detection assembly 21 in position, so that the emitted light of the laser detection assembly 21 is emitted to the top surface of the material pushing part and the reflected light reflected by the top surface of the material stacking part is received. In a preferred embodiment of the present invention, the material of the light-transmitting window 22-1 is quartz glass, which can ensure sufficient mechanical strength and chemical stability while ensuring light transmittance. Further, in order to increase the light transmittance of the light-transmitting window 22-1, a light-transmitting coating is added on the light-transmitting window 22-1, so that the blocking of the light-transmitting window 22-1 on the emergent light and the reflected light of the laser detection assembly 21 is further reduced, and the measurement accuracy is ensured.
In order to ensure the light transmission of the light transmission window 22-1 and prevent dust or other impurities in the stockpile from accumulating on the light transmission window 22-1 to influence the emission and the reception of the monitoring light, the valve 22-2 can be used for covering the outer side of the light transmission window 22-1. The valve 22-2 is positioned at the outer side of the light transmission window 22-1, and the light transmission window 22-1 is completely covered by the valve 22-2 when the valve 22-2 is closed, so that pollutants such as dust and the like are blocked; when the valve 22-2 is opened, the light-transmitting window 22-1 is exposed to the outside, allowing the monitoring outgoing light and the reflected light to pass therethrough. In actual use, in order to avoid the influence of the valve 22-2 on the path of the emergent light and the reflected light, when the valve 22-2 is opened, the light-transmitting window 22-1 is completely exposed to the outside. The light-transmitting window 22-1 is covered by the valve 22-2, so that the condition that the monitoring light path is blocked due to the fact that the light-transmitting window 22-1 is polluted by pollutants can be avoided, and the stability of the monitoring equipment is improved.
Further, in order to facilitate the control of the valve 22-2, as shown in the schematic view of the monitoring module 20 shown in fig. 3 where the light-transmitting window 22-1 is located, a motor 22-4 may be provided, the motor 22-4 drives the valve 22-2 to move, so as to close and open the valve 22-2, and the movement parameters of the motor 22-4, such as start and stop, speed, and the like, are controlled by an external control signal. In a specific use scenario, according to the shape of the housing 22, the light-transmitting window 22-1 and the valve 22-3, the motor 22-4 may realize the opening and closing of the valve 22-2 by using a linear motor to drive the valve 22-2 to translate parallel to the plane, or by using a rotary motor to drive the valve 22-2 to rotate parallel to the plane. The motor 22-4 is used for driving the valve to be opened and closed, so that the automation degree of the device can be improved, the use convenience of the device is improved, the valve can be opened and closed in time, the exposure time of the light-transmitting window 22-1 can be reduced as far as possible under the condition of not shielding monitoring light, and the pollution of pollutants is reduced.
In some embodiments, the valve 22-2 needs to be opened for a longer time, or the dust is more accumulated, and more pollutants may be accumulated on the transparent window 22-1. In order to further ensure the light transmittance of the light-transmitting window 22-1 and reduce the influence of contaminants on the monitoring process, as shown in the schematic plan view of fig. 4, the monitoring module 20 further includes a cleaning member 22-3, the cleaning member 22-3 is movably fixed outside the light-transmitting window 22-1 and moves in a translational manner close to the light-transmitting window 22-1, so as to clean the outside of the light-transmitting window 22-1. Specifically, the cleaning member 22-3 may be composed of a linear motor and a cleaning plastic sheet, the linear motor drives the cleaning plastic sheet to move back and forth along the arrow in fig. 4, and the cleaning plastic sheet scrapes off contaminants on the outer surface of the light-transmitting window 22-1. The light-transmitting window 22-1 is cleaned in a cleaning plastic rubber scraping mode without additionally connecting an air pipe or a water pipe, so that the installation is convenient, potential safety hazards such as water leakage and air leakage cannot be caused, and secondary pollution caused by impurities such as water stains cannot be left on the light-transmitting window 22-1.
In the silo stockpiling height monitoring device provided by the embodiment, each group of monitoring modules 20 can use an independent light source to provide monitoring light for the laser detection assembly 21. On the other hand, in some specific implementation scenarios, in order to save cost, as shown in fig. 5, the laser detection assemblies 21 in each group of monitoring modules 20 in the apparatus provided in this embodiment may also share one light source 30, the light emitted from the light source 30 is coupled with the input optical path of the optical splitter 40, and the light emitted from the light source 30 is divided into multiple channels by the optical splitter 40, and the multiple channels are provided to the multiple laser detection assemblies 21 respectively for use as monitoring light. The optical splitter 40 includes an input port and a plurality of output ports, in order to ensure that each laser detection assembly 21 can obtain monitoring light from the light source 30, the number of the output ports of the optical splitter 40 is not less than the number of the laser detection assemblies 21, and each laser detection assembly 21 is connected with one output port of the optical splitter 40. Specifically, as shown in fig. 5, the laser detection assembly 21 includes a light emitting part 21-1 and a light receiving part 21-2, and an input port of the light emitting part 21-1 of each laser detection assembly 21 is optically coupled to an output port of the optical splitter 40 as an optical path input port of the laser detection assembly 21. The light receiving part 21-2 is coupled to the reflected light path of the light emitted from the light emitting part 21-1, and the electrical interface of the light receiving part 21-2 is used as the electrical interface of the laser detecting assembly 21. The electrical interface includes a power interface, a data interface, a control interface, and the like. Emergent light L1 emitted by the light source 30 is input into an input port of the optical splitter 40, is split by the optical splitter 40 into L2-1 and L2-2 … … L2-n, and is respectively input into input ports of the monitoring modules 20-1 and 20-2 … … 20-n. Specifically, as shown in fig. 6, the input port of the light emitting part 21-1 of the laser detection assembly 21 in each monitoring module 20 emits monitoring light L3 to the top surface of the stack through the light emitting part 21-1, and the monitoring light L3 is reflected by the top surface of the stack to form reflected light L4 and input to the light receiving part 21-2 of the laser detection assembly 21 in each monitoring module 20. The light receiving part 21-2 in each monitoring module 20 receives the reflected light L4 corresponding to the monitoring light emitted from the light emitting part 21-1 in the present monitoring module. The data processing module 10 calculates the distance value obtained by each monitoring module 20 according to the time difference between the emission and the reception of the monitoring light, and further calculates the overall height of the top surface of the windrow. In order to further reduce the cost of the laser detection assembly 21, the light receiving assembly 21-1 may simply use a photo sensor, which receives the reflected light signal and converts the light signal into an electrical signal in real time, and sends the electrical signal to the data processing module 10 in the monitoring module 20 for processing.
In order to ensure the parallelism of the monitoring light, improve the power density of the monitoring light and avoid the light spot expansion or the light path inaccuracy, a collimating optical system can be arranged in the light emitting part 21-1 to collimate and then emit the light received from the light source 30, collimate the monitoring light and further calibrate the light path, thereby avoiding the measurement error caused by the insufficient parallelism of the monitoring light.
In order to reduce the complexity of the optical path and the loss during the optical transmission, the output port of the light source 30 and the input port of the optical splitter 40, and each output port of the optical splitter 40 and the input port of each monitoring module 20 are respectively connected by optical fibers. The optical fiber can be used for establishing a flexible optical path, so that the complex optical path or the loss in the optical transmission process caused by the optical device for establishing the optical path is avoided, meanwhile, the transmission of system data is ensured to have no time delay, the real-time performance of test data is ensured, and the response delay caused by the data time delay is avoided.
Further, in order to ensure that the optical paths of the monitoring light and the reflected light are normal and avoid the monitoring data error caused by the blocking of the monitoring light and the reflected light, light intensity sensing components may be respectively disposed on the light emitting component 21-1 and the light receiving component 21-1, if the difference between the light intensity emitted by the light emitting component 21-1 and the light intensity of the light source 30 is too large, or the difference between the light intensity emitted by the light emitting component 21-1 and the light intensity of the reflected light received by the light receiving component 21-1 is too large, the cleaning component 22-3 is started to clean the light-transmitting window, and if the reflected light intensity after cleaning still cannot reach the standard, other optical path faults may exist, and the data processing module 10 or the monitoring control device 2 is required to send an. The normal operation of a monitoring light path can be guaranteed through light intensity monitoring, and the stability of the device and the accuracy of monitoring data are improved.
Through the device and the structural combination provided by the embodiment, the height of the silo stockpile can be comprehensively and accurately monitored by using a plurality of groups of monitoring modules, and the influence of pollutants such as dust in the stockpile on the monitoring process is avoided by arranging a valve and a cleaning part aiming at the characteristics of the stockpile in the silo so as to acquire more accurate monitoring data.
Example 2:
on the basis of the device for monitoring the height of the silo heap provided by the embodiment 1, the device for monitoring the height of the silo heap can be integrated into an integral silo storage system, so that a system for monitoring the height of the silo heap is provided.
Fig. 7 is a schematic structural diagram of a system for monitoring the silo material level according to this embodiment.
The system comprises a monitoring device 1, a monitoring control device 2 and a silo 3 which are designed according to the device for monitoring the silo stockpiling height provided in the embodiment 1;
the monitoring module 20 in the monitoring device 1 is arranged at the top in the silo 3, and the light-transmitting window 22-1 of the monitoring module 20 faces the top surface of the stockpile in the silo 3. Because the position of the light-transmitting window 22-1 corresponds to that of the monitoring light outlet and the reflected light receiving opening of the laser detection assembly 21, when the light-transmitting window 22-1 faces the top surface of the stacking material, the monitoring light outlet and the reflected light receiving opening of the laser detection assembly 21 also face the top surface of the stacking material, the monitoring light can be emitted to the top surface of the stacking material, and the reflected light of the top surface of the stacking material is received. Since the top surface of the stack is generally a horizontal surface, in order to more accurately obtain the top height of the stack and simplify the data processing process, the emitting optical path and the reflecting optical path of the laser detection assembly 21 are as vertical as possible to the horizontal surface when the monitoring module 20 is arranged.
The monitoring control device 2 interacts with the data processing module 10 in the monitoring device 1 to perform data signal and control signal interaction, and analyzes and monitors the stockpiling height of the silo 3 through the data acquired by the monitoring device 1. When the height of the stockpile is lower than a set value, the monitoring system prompts that the stockpile can be continuously added; when the height of the stockpile is higher than the set value, the monitoring system starts to alarm and can not continue to add the stockpile. In a specific implementation scenario, the stockpile height data acquired by each monitoring module 20 can be simply calculated by the data processing module 10 independent of each monitoring module 20, then the height data is sent to the monitoring control device 2 for analysis, and corresponding warning or control operation is performed according to the analysis result; the data processing module 10 may also be used to analyze the stacking height data obtained by all the monitoring modules 20, and only send the analysis result to the monitoring control device 2, so that the monitoring control device 2 performs corresponding warning or control operation. In a specific embodiment, an appropriate manner may be selected for data analysis and control according to the requirements of data analysis, equipment cost, control complexity, and the like. Further, the data processing module 10 of the monitoring device 1 and the monitoring control device 2 can be integrated in the same set of physical equipment to save cost and installation space; two sets of independent physical equipment can be used to independently complete respective functions, and the flexibility of system installation is improved.
The current passing through the various wires of the monitoring system may cause dust explosions as the stockpiles in the silo may generate dust. Therefore, various wiring between the monitoring device 1 and the monitoring control device 2 needs to use explosion-proof cables to avoid dust explosion and improve system safety.
In order to better fit the surface topography of the top of the silo heap back, the number and location of the monitoring modules 20 should be selected according to the specific shape of the silo 3. In order to better fit the topography of the top surface of the heap, the shape of the distribution area of the monitoring modules 20 needs to be consistent with the shape of the horizontal profile of the top surface of the heap of the silo 3, as shown in fig. 8 and 9, which are schematic views of the mounting points of the monitoring modules 20 in circular and square silos, respectively, each point representing one monitoring module 20. Due to the nature of the silo charging and feeding, the height of the stockpiling in the central region of the silo 3 varies more dramatically and the height fluctuates more than in the edge regions. Therefore, the distance between every two monitoring modules 20 within the preset central area is smaller than the distance between every two monitoring modules 20 outside the preset central area. The closer the area goes to the center, the closer the installed monitoring modules 20 are, the finer the surface topography fitting is, and the more the area goes to the outside, the monitoring modules 20 can be sparse, so that the total number of the monitoring modules 20 is reduced under the condition of ensuring the monitoring accuracy, and the total cost of the system is reduced.
Furthermore, the system for monitoring the height of the silo material pile provided by the embodiment can be linked with the integral main control system of the silo, so as to obtain better monitoring and management effects. In some specific scenes, the monitoring system is connected with a feeding or discharging control system of the silo master control system, the monitoring system is automatically started to detect when feeding or discharging is started, the monitoring is automatically stopped when the feeding or discharging is finished, the feeding is automatically stopped when the stacking height is monitored to exceed the preset height, or the feeding is automatically started when the stacking height is monitored to be lower than the preset height, so that the real-time change of the stacking top surface height in the feeding and discharging processes is conveniently monitored, and different possible stacking height conditions are timely processed. In some concrete scenes, the silo is provided with an automatic stacking device for stacking, and under the condition that the stacking operation can be carried out, the stacking device is started to stack the top of the stacking material before the monitoring light is started, so that the top of the stacking material is kept as flat as possible, the accuracy of monitoring data is improved, and the complexity of data processing is reduced.
By the silo stacking height monitoring system, the height of the stacked materials in the silo obtained by the silo stacking height monitoring device can be analyzed and processed, and different processing can be carried out by matching with a main control system of the silo according to different height conditions, so that the stacked materials in the silo can be kept at a proper height. Meanwhile, the reasonable layout of the monitoring modules 20 in the device for monitoring the silo stacking height better fits the surface appearance of the stacking height, and improves the monitoring accuracy.
Example 3:
on the basis of the apparatus for monitoring the silo windrow height provided in the above embodiment 1 and the system for monitoring the silo windrow height provided in embodiment 2, the present invention provides a method for monitoring the silo windrow height using the system for monitoring the silo windrow height.
It will be understood by those skilled in the art that all or part of the steps in the processing procedure of the steps of the embodiment 3 may be implemented by a program instructing relevant hardware in the system for monitoring the silo-pile height, and the steps of the embodiment 3 may be stored in a readable storage medium existing in each of the monitoring device 1 and the monitoring control device 2 in the system for monitoring the silo-pile height, and the storage medium may include: read Only Memory (ROM), Random Access Memory (RAM), magnetic or optical disks, and the like.
As shown in fig. 10, the method for monitoring the silo material stacking height provided by the embodiment of the invention comprises the following specific steps:
step 101: the system for silo stockpiling height monitoring proposed according to example 2 deploys a monitoring module 20 in the silo 3.
Before monitoring the height of the stockpile, the monitoring module 20 in the monitoring device 1 needs to be deployed at a proper position in the silo 3 according to the technical scheme in the embodiment 2 to acquire more accurate monitoring data and realize the best monitoring effect. After the monitoring device 1 is deployed, the system for monitoring the silo stockpile height can use various components in the monitoring device 1 to complete the monitoring process according to steps 102 to 105 under the control of the monitoring control device 2.
Step 102: the monitoring module 20 sends a monitoring light signal to the top of the pile.
Step 103: the monitoring module 20 obtains a reflected light signal obtained by reflecting the monitoring light signal by the top of the stockpile.
Step 104: the data processing module 10 obtains the reflected light signal data of all the monitoring modules 20 to obtain the stockpile top height data.
In steps 102 and 103, the laser detection assembly 21 in the monitoring module 20 emits monitoring light and receives reflected light to realize the initial acquisition of height monitoring related data, and then the calculation is performed in step 104 to obtain the stockpile top height data. In a specific implementation scenario, the step 104 may be implemented by using different technical solutions, the laser detection assembly 21 may directly obtain the distance between the laser detection assembly 21 and the top surface of the stack by using an existing laser range finder, and the data processing module 10 directly calculates the height of the top surface of the stack according to the obtained distance value; it is also possible to use a combination of a laser transmitter and a light sensor to transmit only monitoring light and receive reflected light, and the data processing module 10 calculates the distance between the laser detection assembly 21 and the top surface of the pile and further calculates the height of the top surface of the pile according to the time difference between the time when the monitoring light is transmitted and the time when the reflected light is returned from each monitoring module 20.
Step 105: the monitoring control device 2 judges the state of the top height of the pile according to the top height data of the pile obtained by the data processing module 10.
After the data of the top heights of the piles in all the monitoring modules 20 are obtained, all the data can be integrated, the state of the top heights of the piles is further judged, and whether the top heights of the piles are higher than a set safety height threshold value or not is determined. In different specific application scenarios, different ways of calculating and monitoring the windrow top height in step 105 may be used. The following list simply lists the common way of calculating the height of the top of the material pile, but the practical use is not limited to the following way, and other ways of calculating and monitoring the height of the material pile in the silo by using the monitoring data acquired by other systems based on silo material pile height monitoring can also be used according to the practical situation. In a specific use scenario, the safety height threshold may be adjusted according to actual needs.
(1) And searching the highest value in the stacking top height data of all the monitoring modules 20, and if the highest value of the stacking top height data exceeds a preset safety height threshold value or the distance between the monitoring modules 20 and the stacking top is smaller than a preset safety distance threshold value, judging that the stacking height is too high. The method can simply, conveniently and quickly judge the height state of the piled materials, has strong monitoring real-time performance, is suitable for scenes with higher safety requirements, and can find the condition of over-high piled materials in time; on the other hand, the method can accurately acquire the height data under the condition that the top surface of the stacking material is relatively flat, but errors may occur in the scene with an uneven shape of the top surface of the stacking material due to the arrangement position of the monitoring module 20 and the like, so that the method is not suitable for the scene with large fluctuation of the top surface of the stacking material or high requirement on the accuracy of the calculated data. Meanwhile, the scheme has low requirements on the calculation performance of the data processing module 10 and the monitoring control device 2, and can be realized by using equipment with low cost.
(2) And fitting the shape of the top of the piled material according to the positions of the different monitoring modules 20 and the acquired reflected light signal data to acquire three-dimensional data of the shape of the top of the piled material. The method is complex in calculation and long in calculation time, can accurately acquire the shape of the top of the stacking material, can monitor the height state of the stacking material more accurately and completely, and is suitable for scenes with large fluctuation of the top surface of the stacking material or the requirement on the calculation precision of the top surface height data. Meanwhile, the scheme has high requirements on the calculation performance of the data processing module 10 and the monitoring control device 2, and needs to be implemented by using equipment with high cost. Specifically, in the specific implementation scenario of this embodiment, different fitting manners may be selected according to different computation complexities and required data accuracy to fit the topography of the top of the pile, such as an interpolation method, a polishing method, a least square method, and the like.
In the specific implementation manner of this embodiment, since the sectional area of the silo is generally not large, when performing three-dimensional fitting, a correlation plane fitting method may be adopted to establish a mathematical model as in formula 1 for fitting:
hi=A0+A1xi+A2yi+A3xiyi(formula 1))
Wherein A is0、A1、A2、A3Are fitting coefficients. The coal pile thickness corresponding to each point is hiThe coordinate of each point in the plane of the silo is xiAnd yi. Due to the fact that x is in practical useiAnd yiThe value of (a) corresponds to the horizontal position coordinates of the monitoring module 20, while the monitoring module 20 is fixed in position, so that x is calculatediAnd yiThe value of (c) may be preset.
Then, fitting is carried out by using an approximation principle of a least square method through a formula 2:
Figure BDA0002561323550000181
n is the number of the used monitoring modules 20, each monitoring module obtains a corresponding measured distance value, and the obtained measured distance value array is combined to approach a preset parameter value, the more the set measured distance array number is, the more accurate the test result is, and the better the curve fitting effect is. After the curved surface fitting is carried out, three-dimensional data of the appearance of the top of the stacking material can be obtained according to the fitted curved surface equation, and the heights of different positions of the top of the stacking material can be accurately monitored.
Through steps 101 to 105, the device for monitoring the silo stacking height provided in embodiment 1 and the system for monitoring the silo stacking height provided in embodiment 2 can be used to monitor the stacking height in the silo, so as to conveniently and accurately obtain the state of the top surface height of the stack, provide safety indication for feeding and discharging in the silo, and avoid potential safety hazards or abnormal operation of the feeding and discharging system caused by the fact that the top surface height of the stack exceeds a safety height threshold.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.

Claims (10)

1. A silo windrow height monitoring device, characterized in that:
comprises at least one data processing module (10) and at least one group of monitoring modules (20);
each group of monitoring modules (20) comprises at least one laser detection assembly (21) and a shell (22), the laser detection assembly (21) is hermetically sealed in the shell (22), an electrical interface of the laser detection assembly (21) is used as an external electrical interface of the monitoring module (20), the shell (22) comprises a light-transmitting window (22-1) and a valve (22-2), the positions of a monitoring light outlet and a reflected light receiving port of the light-transmitting window (22-1) and the laser detection assembly (21) correspond to each other, the valve (22-2) is positioned outside the light-transmitting window (22-1), the light-transmitting window (22-1) is completely covered by the valve (22-2) when the valve (22-2) is closed, and the light-transmitting window (22-1) is exposed to the outside when the valve (22-2) is opened;
the data processing modules (10) are coupled to respective ports of the external electrical interface of each set of monitoring modules (20).
2. The apparatus of claim 1, wherein the apparatus comprises:
the device also comprises a light source (30) and a light splitter (40);
the optical splitter (40) comprises an input port and at least one output port, wherein the number of the output ports is not less than that of the laser detection assemblies (21);
the emergent light of the light source (30) is coupled with the input port light path of the optical splitter (40);
the laser detection assembly (21) comprises a light emitting component (21-1) and a light receiving component (21-2), wherein an input port of the light emitting component (21-1) of each laser detection assembly (21) is optically coupled with one output port of the optical splitter (40) to serve as an optical path input port of the laser detection assembly (21), the light receiving component (21-2) is optically coupled with a reflection optical path of light emitted by the light emitting component (21-1), and an electrical interface of the light receiving component (21-2) serves as an electrical interface of the laser detection assembly (21).
3. The apparatus of claim 1, wherein the apparatus comprises:
the laser detection assembly (21) further comprises a cleaning component (22-3), wherein the cleaning component (22-3) is movably fixed on the outer side of the light-transmitting window (22-1) and is in translational motion close to the light-transmitting window (22-1) so as to clean the outer side of the light-transmitting window (22-1).
4. A system for monitoring silo windrow height, comprising:
monitoring device (1), monitoring control device (2) and silo (3) comprising a device design for silo stockpiling height monitoring as set forth in any one of claims 1 to 3;
a monitoring module (20) in the monitoring device (1) is arranged at the top in the silo (3), and a light-transmitting window (22-1) of the monitoring module (20) faces to the top surface of the stockpile in the silo (3);
the monitoring control device (2) and the data processing module (10) in the monitoring device (1) carry out interaction of data signals and control signals, so that the stockpiling height of the silo (3) can be analyzed and monitored through the data obtained by the monitoring device (1).
5. The system of silo windrow height monitoring of claim 4, wherein:
the shape of the distribution region of the monitoring modules (20) is consistent with that of the top of the silo (3), and the distance between every two monitoring modules (20) positioned in the range of the preset central region is smaller than that between every two monitoring modules (20) positioned outside the range of the preset central region.
6. The system of silo windrow height monitoring of claim 4, wherein:
the wiring between the monitoring device (1) and the monitoring control device (2) is an explosion-proof cable.
7. A method of monitoring silo windrow height, characterized by:
the system for silo stockpiling height monitoring as set forth in any one of claims 4-6 deploying a monitoring module (20) in the silo (3);
the monitoring module (20) sends a monitoring optical signal to the top of the stockpile;
the monitoring module (20) acquires a reflected light signal obtained by reflecting the monitoring light signal by the top of the stockpile;
the data processing module (10) obtains the height data of the top of the stockpile according to the reflected light signal data of all the monitoring modules (20);
the monitoring control device (2) judges the state of the top height of the stockpile according to the top height data of the stockpile obtained by the data processing module (10).
8. A method of silo pile height monitoring as defined in claim 7 wherein the obtaining of pile top height data comprises:
and fitting the morphology of the top of the stockpile according to the horizontal positions of the different monitoring modules (20) and the acquired reflected light signal data to acquire three-dimensional data of the morphology of the top of the stockpile.
9. The method of silo windrow height monitoring of claim 7, wherein the data processing module (10) obtains reflected light signal data for all monitoring modules (20) including:
the data processing module (10) respectively calculates the stacking height of the corresponding position of each monitoring module (20) according to the time difference between the sending time of the monitoring light of each monitoring module (20) and the returning time of the reflected light.
10. The method of silo windrow height monitoring of claim 7, further comprising:
when the monitoring module (20) is required to send a monitoring optical signal to the top of the stockpile and the monitoring module (20) is required to acquire a reflected optical signal, the monitoring control device (2) starts a valve (22-2) on the monitoring module (20).
CN202010607307.3A 2020-06-30 2020-06-30 Device, system and method for monitoring silo stacking height Pending CN111895922A (en)

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CN105527627A (en) * 2016-01-18 2016-04-27 深圳市金立通信设备有限公司 Laser ranging device, camera device and terminal
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