CN113330284A - 电容式液位传感器和液体传感器组件 - Google Patents

电容式液位传感器和液体传感器组件 Download PDF

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CN113330284A
CN113330284A CN201980088685.0A CN201980088685A CN113330284A CN 113330284 A CN113330284 A CN 113330284A CN 201980088685 A CN201980088685 A CN 201980088685A CN 113330284 A CN113330284 A CN 113330284A
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K·何
W·E·谢泼德
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Charles Austen Pumps Ltd
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Abstract

一种电容式液位传感器(1)。该传感器包括呈舌状体形式的传感器本体，该传感器本体具有自由悬垂部(3)，该自由悬垂部分在其最下端延伸至远侧末端(6)。一组间隔开的电容电极(7)沿着舌状体向远侧末端延伸。在使用中，当舌状体的远侧末端(6)浸入液体的本体中时，电极(7)之间的电容根据液体本体的深度而变化。至少对于舌状体的自由悬垂部分的下半部分，舌状体的宽度在向下方向上增大。

Description

电容式液位传感器和液体传感器组件
技术领域
本发明涉及电容式液位传感器和液体传感器组件。
背景技术
该传感器特别地设计用于测量罐中的冷凝物液位。然而，该传感器也可应用于需要测量液位的其他情况。
冷凝罐广泛用于空调、除湿器、冰箱、冷凝锅炉等。它们通常位于罐下方，以接纳来自主设备的冷凝水。
当冷凝物收集在罐中并且液位上升到高于上限阈值时，传感器发出信号，该信号由控制器解释，然后控制器将启用泵以对罐进行排放。当液位降低到低于下限阈值时，泵被停用。为了降低泵的磨损、功耗和噪声，阈值条件的准确测量是必要的。
传统上，浮子传感器用于检测阈值液位。但是它们体积大，容易被卡住。因此，我们使用了基于热敏电阻的传感器。尽管这解决了浮子传感器的诸多问题中的一些问题，但它仍有许多缺点。它仍然相对体积大，需要相对较高的电力。
因此，我们正在开发一种电容式传感器，它可以更小，需要更少的电力。此外，它对变化的液位敏感，而浮子和热敏电阻传感器只是简单地通过触发on/off开关来检测何时到达阈值。因此，电容式传感器允许跟踪各个液位之间的填充速率，并可以允许在各种不同液位提供警报。
随着罐中冷凝物液位的下降，冷凝液袋状体往往会由于毛细作用而从冷凝物主体脱离，并保留在电容式传感器与周围机械部件之间的间隙中。液体袋状体的大小不一致，并且是不可预测的。结果，传感器读数变得不准确。例如，保留液体的存在可能导致传感器记录信号，该信号指示液体仍然存在，即使当液体的主体已经下落到低于下限阈值时。这导致泵不必要地运转。另一方面，如果在存在截留液体的情况下对传感器进行了校准，这可能导致传感器稍后报告液位低于实际液位，在这种情况下，泵将很快停止。
解决这个问题的一种方法是将传感器与任何周围机械部件隔开。然而，在大多数应用中，商业动机是减小收集罐的尺寸，使其适合小空间。因此，不仅传感器本身需要很小，还需要将其安装在紧邻其他部件如罐壁、支架或保护罩的地方。
总有一些水保留在收集罐中低于下限阈值处，因为不希望完全排空罐，因为这将需要在液体和空气的混合物通过的情况下运行泵，这样做噪音大且效率低。然而，对于较小的罐，这种保留水的体积占总罐体积的百分比成比例地变大，从而加剧了测量不准确的问题。已经发现，当传感器与相邻部件之间的间隙为6mm或更小时，会出现附着水问题。因此，需要这样一种解决方案：这种解决方案能够处理附着水的问题，同时允许传感器位于周围机械部件的6mm范围内。
发明内容
根据本发明，提供了根据权利要求1的电容式液位传感器。
当传感器紧邻周围部件放置时，通常会有一个竖向壁。因此，舌状体在向下方向上宽度的增大产生了在向下方向上变窄的间隙。当液体主体中的液位下降时，留在该间隙中的任何液体往往会在毛细作用下被向下拉到该间隙的最窄部分。因此，不是被截留在沿舌状体长度的不可控位置，而是使任何截留的液体收集在更好地限定的和更可控的位置。
传感器被构造成使得电极在未到达舌状体的自由悬垂部的最宽部分处终止。利用这种布置，任何截留的液体都可以被抽吸到电极端部下方的位置，从而不会干扰液位感测。此外，传感器可以被定位成使得传感器的最宽部分低于其中放置它的罐的下限阈值，使得任何截留的液体都被吸入液体主体。
舌状体可以具有圆锥形或其他“三维”形状，并且可以在一个维度或两个维度中具有增大的宽度。然而，优选地，舌状体是平的。这种平坦结构减小了舌状体靠近周围结构的表面积。优选地，舌状体是印刷电路板(PCB)。这允许电极被安装在PCB上，并且传感器所需的所有其他电连接可以以利用PCB制造的低成本大规模生产技术的方式进行。PCB可以方便地支持传感器所需的电子电路。此外，PCB通常由机械上坚固且不吸潮的玻璃纤维制成。
舌状体可以例如通过粘附到周围结构上来安装。然而，优选地，舌状体在与远端相对的一端具有连接部，通过该连接部可以安装舌状体。优选地，连接部设置有电接触件，因为这允许舌状体以容易的方式安装，并且以提供传感器所必需元件的简单安装方式并提供这些元件的容易连接的方式，与PCB一起安装。
因为传感器可以在相对较小的空间中使用，所以它适用于舌状体被护罩包围的情况。这为传感器本体提供了机械保护。例如，当舌状体与最近的相邻构件之间的最小间隙小于6mm时，可以使用传感器。
根据本发明的第二方面，提供了根据权利要求7的液体传感器组件。这提供了上文中提到的关于当液体滴落时间隙变窄的优点。可以通过使壳体具有的倾斜部分，或者通过使得传感器相对于壳体而倾斜，来提供变窄的间隙。然而，优选地，减小的间隙由根据权利要求1的传感器提供。
壳体可以设置有护罩，但是也可以是罐和/或盖的一部分。
优选地，传感器与壳体之间在壳体最窄部分处的间隙为6mm或更小。
附图说明
现在将参照附图描述根据本发明的传感器的示例，附图中：
图1是传感器和用以表示比例的尺子的平面图；
图2是包括传感器的组件的局部示意图；
图3是根据本发明的传感器和周围壳体的前视图；而
图4和5是类似于图3的视图，通过与图3的比较，示出了不是根据本发明的传感器。
具体实施方式
图1和图2所示的传感器形成在平坦的印刷电路板上。然而，它可以形成在其他基板上，无论是平坦的还是其他情况。
广义地说，传感器1分为安装部件2和悬垂部件3，传感器1经由安装部件2安装到周围的壳体，悬垂部件3从安装部件向下悬垂。从图2中可以明显看出，安装部件2呈现为圆柱形包覆模的形式，其容纳并密封传感器1上部的电路。它由弹性体形成，从而可以提供与周围安装件的压缩配合。如从图中可以看出，有明确限定的颈部4，该颈部代表安装部分2紧邻下方的悬垂部分中的变窄部分。从颈部延伸的是主要部分5，其中宽度在悬垂部分的大部分长度上略微增大。主要部分5终止于远侧末端6，远侧末端6在此示出为具有半圆形构造，但是同样可以是平的，使得主要部分的锥形一直延伸到远侧末端。替代地，它可以具有任何其他构造，例如尖的或凹进的构造。
一组电极7沿着主要部分5延伸，并且可选地遵循主要部分5的锥形彼此分开。它们的终止位置远未到达远侧末端6，所述终止位置在从远端开始沿着悬垂部分大约四分之一处。其效果描述如下。
电极7通过导电迹线8连接到安装部分2。导电迹线8通向安装部分2，安装部分2设置有传感器所需的必要电路9，并且设置有电连接器10，其用以向传感器传输电力和从传感器传输信号。它还设有孔11，为附连的电缆提供应变消除。
如上所描述的传感器1如图2所示安装在罐中。罐包括主体20和盖子21，护罩22从盖子21延伸。
传感器1安装在盖子21上，悬垂部分3从盖子向下悬垂，并且远侧末端被示出为浸没于保持在罐底部的水的主体W中。电极7之间的电容随着传感器1浸入水体W中的深度而变化。
罐的确切性质对本发明来说并不重要，事实上，本发明的重要特征之一是它允许传感器改装于许多类型的现有罐中。原因如下所叙述。
通过将图3与图4和图5进行比较，可以理解本发明提供的技术效果。图3是根据本发明的，因为传感器1在朝向远端的向下方向上宽度增大。当将其放置在具有平行侧面的隔热护罩22内时，在传感器1的两侧产生间隙23，所述间隙在向下的方向上宽度减小。由于这种设置方式，毛细作用力使得液体向下流向间隙23的最窄部分24。
图2示出了在对应于罐内最低阈值的位置处的液体W的主体。可以理解的是，该液位与图3中截留液体的液位大致相同，从而使其可以重新加入液体的主体。罐内液体的液位最高阈值由图3中的线X描绘。
相比之下，图4是使得传感器在与本发明所要求的方向相反方向呈锥形的效果。一些液滴D已经积聚在护罩22的最低点，并且在悬垂部分3两侧的区域中形成液体膜L。在这种情况下，毛细力在相反的方向作用，将液体保持在原位。
类似地，在图5中，悬垂部分3和护罩22的表面平行，液体再次积聚在间隙26中。在图4和5中，在电极10附近有大量不合期望的液体，这将干扰传感器的读数。相比之下，本发明将这种液体引导到远离电极的明确限定的位置，使得这种情况要么根本不会干扰，要么影响小得多且可预测得多。

Claims (9)

1.一种电容式液位传感器，所述传感器包括呈舌状体形式的传感器本体，所述传感器本体具有自由悬垂部，所述自由悬垂部延伸至在使用中在其最下端处的远侧末端；
沿舌状体向远侧末端延伸的一组间隔开的电容电极，其中，在使用中，当所述舌状体的所述远侧末端浸入液体本体中时，所述电极之间的电容根据液体本体的深度而变化；
其中，所述舌状体的宽度在朝向所述远侧末端的方向上增大，从而至少对于所述舌状体的自由悬垂部分的下半部的一部分限定了所述舌状体的所述自由悬垂部的最宽部分；并且其中，所述电极在未到达所述舌状体的自由悬垂部的最宽部分处终止。
2.根据权利要求1所述的传感器，其中，所述舌状体是平的。
3.根据任一前述权利要求所述的传感器，其中，所述舌状体是印刷电路板。
4.根据任一前述权利要求所述的传感器，其中，所述舌状体在与所述远端相反的端部具有连接部，所述舌状体能够通过所述连接部而被安装。
5.根据权利要求5所述的传感器，其中，所述连接部设置有电接触件。
6.根据前述权利要求中任一项所述的传感器，其中，所述舌状体被护罩包围。
7.一种液体传感器组件，其包括：
根据任一前述权利要求所述的电容式液位传感器，所述传感器包括舌状体形式的传感器本体，所述传感器本体具有延伸至在使用中在其最下端处的远侧末端的自由悬垂部，以及沿所述舌状体向远侧末端延伸的一对间隔开的电容电极，其中，在使用中，当所述舌状体的所述远侧末端浸入液体本体中时，所述电极之间的电容根据所述液体本体的深度而变化；
所述组件还包括包围所述传感器的舌状体的壳体，其中，对于所述舌状体的所述自由悬垂部的下半部的至少一部分，所述传感器与所述壳体之间的间隙在向下的方向上减小。
8.根据权利要求7所述的组件，其中，所述壳体由罐和/或盖的一部分提供。
9.根据权利要求7至8中任一项所述的组件，其中，所述传感器与所述壳体之间的间隙在其最窄部分小于6mm或更小。
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