CN114152319B - On-site detection method and detection device for side-mounted liquid level meter of tank truck - Google Patents
On-site detection method and detection device for side-mounted liquid level meter of tank truck Download PDFInfo
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- CN114152319B CN114152319B CN202210116880.3A CN202210116880A CN114152319B CN 114152319 B CN114152319 B CN 114152319B CN 202210116880 A CN202210116880 A CN 202210116880A CN 114152319 B CN114152319 B CN 114152319B
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Abstract
The invention discloses a field detection method and a field detection device for a side-mounted liquid level meter of a tank car, which comprise the steps of inputting basic data; measuring uplink and downlink process data; is simulated to obtainVAnd withSA comparison table; is calculated to obtainθAndHa comparison table; selecting a detection point, and determining the readings of an upper travel liquid level meter and a lower travel liquid level meter; calculating the error and return difference of the liquid level meter; and (6) judging the result. The detection device comprises a supporting platform, a motor, a speed reducer, a torque sensor, a liquid level meter connecting piece, an angle sensor, a video monitor and a data processing system; the measurement results are sent to a data processing system. The buoyancy force measuring device has the beneficial effects that the buoyancy force is obtained by measuring the torque, and the problem that the buoyancy force borne by the liquid level meter cannot be directly measured on site is solved. Simulating and calculating to obtain different anglesVAndSand the liquid level height is determined by comparing the table, so that the problem that the liquid level height cannot be determined by adopting an analytical method is solved. Is suitable for floating balls in various forms. The detection device has simple structure and convenient installation.
Description
Technical Field
The invention relates to the field of special equipment inspection and detection; in particular to a field detection method and a detection device for a side-mounted liquid level meter of a tank car.
Background
The tank body is at least provided with a liquid level meter, and the liquid level meter should have a corresponding relation between liquid level indication scales and volume. At present, a liquefied gas tank truck mainly adopts a rotary pipe type liquid level meter, a rotary floating ball liquid level meter and a side-mounted liquid level meter, wherein the former two types are traditional liquid level meters, the side-mounted liquid level meter is a new product, and how to test the side-mounted liquid level meter is an actual problem facing an inspection mechanism. The side-mounted liquid level meter and the former two are different in structure: all parts of the liquid level meter are arranged on the same cross section and are arranged in the middle of the cylinder body, the change of the liquid level drives the floating ball to rotate in the cross section and drives the bevel gear, the transmission shaft and the pointer to rotate, and numerical values are displayed on the meter; secondly, the floating ball of the side-mounted liquid level meter adopts an oblong floating ball (the middle is a cylinder, and the two ends are hemispheres) instead of a spherical floating ball, in the process of lifting the liquid level, the relative position of the oblong floating ball and the liquid level is continuously changed along with the difference of the rotation angle, the volume of the part below the liquid level of the floating ball and the rotation angle of the floating ball show a complex nonlinear corresponding relation, the volume of the part below the liquid level of the floating ball is very difficult to calculate by adopting an analytical method, namely the intersection line of the floating ball and the liquid level is continuously changed, the measuring reference cannot be directly determined, and the change of the liquid level cannot be indirectly measured by a steel tape; and thirdly, if the liquid level meter is detected after being disassembled, a new random error is generated in the installation process because the liquid level meter is driven by the gear and is limited by the installation precision due to a supporting structure.
At present, the inspection of the liquid level meter mainly adopts a water tank method for inspection after disassembly, and the field inspection requirement of a side-mounted liquid level meter cannot be met; the liquid level is indirectly measured by using the steel tape according to the simulation method, and the measurement reference surface cannot be determined due to the fact that the side-mounted floating ball is of an oblong structure, so that the measurement cannot be realized; therefore, the detection work of the side-mounted liquid level meter becomes a difficulty of the tank car detection work.
Disclosure of Invention
The invention aims to provide a method and a device for detecting a side-mounted liquid level meter on site.
The invention adopts the technical scheme that the field detection method of the side-mounted liquid level meter of the tank car comprises the steps of
A. Entering basic data in a data processing system, including cylinder radiusRDistance from the center of the floating ball of the liquid level meter to the rotating shaftLDensity of liquidρLength of the floating balllDiameter of the floating balld；
B. The motor drives the liquid level meter to rotate at a constant speed to complete torqueM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′Synchronous measurement; torque ofM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′Measured by a torque sensor, an angle sensor and a video monitor respectively, and the measured torqueM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′Transmitting the data to a data processing system in real time;
C. obtaining rotation angles of floating balls of different liquid level meters through simulation calculation in a data processing systemθLower float to drain off liquid volumeVThe central position of the floating ball relative to the liquid levelSA reference table of (1);
D. b, measuring the rotation angle of the floating ball of the liquid level meter according to the step BθTorque of the motorM FObtaining the rotation angle of the floating ball of the liquid level meter by calculating and looking up the tableθHeight of liquid levelHA reference table of (1);
E. selecting at least five detection points; for a certain detectionPoint J, viewing video monitor data to obtain a level gauge readingh′The actual liquid level at the detection point J ish；
F. Calculating the error of the liquid level meter at each detection point
Return difference of liquid level meter
；
G. And (3) judging whether the liquid level meter is qualified: when the maximum error is satisfied
In the step B, the uniform rotation of the motor comprises forward uniform rotation of the motor and reverse uniform rotation of the motor;
when the motor rotates forwards at a constant speed, the liquid level meter is driven to rotate from the lowest liquid level to the highest liquid level, and the torque of the upper stroke is completedM F1Upper stroke liquid level meter floating ball rotation angleθ 1 And the indication of the upstroke liquid level meter
Measuring (2); when the motor rotates reversely at a constant speed, the liquid level meter is driven to rotate from the highest liquid level to the lowest liquid level, and the lower stroke torque is completedM F2Lower stroke liquid level meter floating ball rotation angleθ 2 And down stroke level meter reading
Measuring (2);
step C, establishing a floating ball model, wherein the length of the floating ball islThe diameter of the floating ball isd，The length direction of the floating ball is coincided with the vertical direction, and the chair is satThe origin of the standard system is positioned at the center of the floating ball; establishing a dimension ofl*d*dA cuboid circumscribed to the floating ball;
the cuboid is uniformly sampled, and the number and the density of sampling points depend onnThe coordinates of the sampling point arex i ，y j ，z k ）；
According to the diameter of the floating balldAnd lengthlDetermining a sampling point (x i ，y j ，z k ) Whether the ball is in the floating ball or not, the judged result is assigned toP ijk ；
When the sampling point is located in the floating ball, the sampling point will beP ijk The value is assigned to 1; otherwise it will beP ijk The value is assigned to 0;
when the floating ball of the liquid level meter rotates by an angle ofθAt a liquid level ofHThe central position of the liquid level relative to the floating ballS=H-（R-L·cos θ) When the temperature of the water is higher than the set temperature,Hvalue is inR- L·cosθ-l/2，R- L·cosθ+l/2]In the interval of the time interval,
to the coordinates of the sampling point: (x i ，y j ，z k ) Performing coordinate transformation to obtain transformed coordinates
；
When in use
Then the sampling point after coordinate transformation is positioned at the height of liquid levelHThe following;
judging whether the sampling point is in the floating ball and at the liquid levelHThe result of the judgment is assigned to
The judgment formula is as follows:
when the sampling point is in the floating ball and at the liquid levelHWhen the following, will
The value is 1, otherwise, the value is 0;
volume of liquid displaced by the floatV： 
Wherein n is a sampling density factor;
obtain the rotation angle of the floating ball of the liquid level meter asθThe central position of the liquid level relative to the floating ball isSVolume of liquid displaced by the floatV(ii) a Changing the value of the central position S of the liquid level relative to the floating ball, calculating according to the steps, and outputting the result as the rotation angle of the floating ball of a certain liquid level meterθVolume of liquid displaced by lower floatVThe central position of the floating ball relative to the liquid levelSA reference table of (1); change the rotation angle of the floating ball of the liquid level meterθCalculating according to the steps to obtain the rotation angles of the floating balls of the different liquid level metersθLower float to drain off liquid volumeVThe central position of the floating ball relative to the liquid levelSA reference table of (2);
step D, rotating angle of a floating ball of the liquid level meterθHeight of liquid levelHThe comparison table comprises an upper stroke liquid level meter floating ball rotation angle and liquid level comparison table and a lower stroke liquid level meter floating ball rotation angle and liquid level comparison table;
the rotation angle of the floating ball of the upstroke liquid level meter is respectively measured according to the upstroke and the downstrokeθ 1 Torque of upstrokeM F1Lower stroke liquid level meter floating ball rotation angleθ 2 Torque of down strokeM F2And the rotation angle of the floating ball of the upper stroke liquid level meter is obtained by calculationθ 1 And the rotation angle of a floating ball of the down stroke liquid level meter isθ 2 Volume of liquid actually displaced by the floatV 1 And volume of liquidV 2 (ii) a The calculated volume of the liquid actually discharged by the floating ballV 1 And a liquidVolume ofV 2 And the volume of the liquid discharged by the floating ball obtained by simulation according to the step CVThe central position of the floating ball relative to the liquid levelSComparing the volume values in the comparison table and performing interpolation calculation to determine the central position of the liquid level relative to the floating ball, and further calculating to obtain the rotation angle of the floating ball of the upper stroke liquid level meterθ 1 Corresponding liquid level heightH 1 And the rotation angle of the floating ball of the down stroke liquid level meterθ 2 Corresponding liquid level heightH 2 The output is a comparison table of the rotation angle and the liquid level height of the floating ball of the upper stroke liquid level meter and a comparison table of the rotation angle and the liquid level height of the floating ball of the lower stroke liquid level meter;
step E, the liquid level meter displaysh′Including the indication of upstroke level meter
And down stroke level meter reading
Checking the data of the video monitor according to the comparison table of the upper stroke rotation angle and the liquid level height and the comparison table of the lower stroke rotation angle and the liquid level height obtained in the step D to obtain the indication number of the upper stroke liquid level meter corresponding to the detection point J
And down stroke level meter reading
The actual liquid level at the detection point J ishActual liquid level height of detection point JhThe numerical value of (2) is obtained from a comparison table of the rotating angle and the liquid level height of the floating ball of the upper stroke liquid level meter and a comparison table of the rotating angle and the liquid level height of the floating ball of the lower stroke liquid level meter.
Step F, error of the liquid level meter at each detection point
Return difference of liquid level meter at each detection point
；
Wherein the content of the first and second substances,H m in order to be the measuring range of the liquid level meter,
in order to indicate the number of the upper stroke liquid level meter,
is the indication number of the liquid level meter of the downstroke,h′in order to indicate the number by the liquid level meter,hthe actual liquid level height of the detection point is obtained.
A tank car side-mounted level gauge on-site detection device is used for realizing a tank car side-mounted level gauge on-site detection method, and comprises a supporting platform, a motor, a speed reducer, a torque sensor, a level gauge connecting piece, an angle sensor, a video monitor mounting bracket, a video monitor and a data processing system; the motor and the speed reducer are arranged on the supporting platform, the output end of the speed reducer is connected with the torque sensor, and the torque sensor and the angle sensor are connected with the liquid level meter through the liquid level meter connecting piece; the video monitor mounting bracket is provided with a video monitor; and the data of the torque sensor, the angle sensor and the video monitor are sent to a data processing system through transmission lines.
The liquid level meter connecting piece is a double-U-shaped groove, a round shaft of the U-shaped groove is of a round hollow structure, and the U-shaped groove is connected with a floating ball rod of the liquid level meter to be measured.
The supporting platform is of a tetrapod structure, four supporting legs of the tetrapod are respectively arranged in two mutually perpendicular directions and form an included angle of 5-20 degrees with the vertical direction, the four supporting legs are divided into an upper section supporting leg and a lower section supporting leg, and the bottom of the lower section supporting leg is of a spherical structure.
One end of the video monitor mounting bracket is of a circular hoop structure and is fixed on a liquid level meter instrument panel, the other end of the video monitor mounting bracket is circular or square and is used for mounting a video monitor, and the axis of the video monitor is superposed with the axis of the liquid level meter instrument panel; the video monitor is fixed right above the liquid level meter through the mounting bracket.
The invention has the advantages that the liquid level meter is driven to rotate by the motor and the speed reducer, the buoyancy value is indirectly obtained by measuring the torque, and further the liquid volume discharged by the floating ball is obtained, thereby solving the problem that the buoyancy borne by the side-mounted liquid level meter cannot be detected on site and improving the working efficiency. The method is provided by a simulation calculation method, and the comparison table of the volume of the liquid discharged by the floating ball and the position of the liquid level relative to the center of the floating ball under different rotation angles is obtained by utilizing the rapidness and the convenience of the computer calculation, so that the actual liquid level height is determined, the problem that the actual liquid level height cannot be determined by adopting an analytic method is solved, and a theoretical basis and a solution are provided for the detection of the side-mounted liquid level meter. The invention is suitable for floating balls in various forms, in particular to an oblong floating ball. The detection device has simple structure and convenient installation, is particularly suitable for the tank car with the cylinder body of the circular arc surface structure, and ensures the stability of the detection environment.
Drawings
FIG. 1 is a flow chart of a side-mounted level gauge in-situ testing method;
FIG. 2 is a flow chart of a computer simulation procedure;
FIG. 3 is a schematic view of a force analysis of the gauge;
FIG. 4 is a schematic diagram of the torque applied to the liquid level meter during uniform rotation;
FIG. 5 is a schematic diagram illustrating the basic data for level gauge detection;
FIG. 6 is a schematic diagram showing the volume of liquid displaced by the float and the position of the liquid surface at different liquid level heights for a certain rotation angle;
FIG. 7 is a schematic view of a coordinate system of a float ball model for illustrating the size of the float ball and for establishing the float ball in a computer;
FIG. 8 is a diagram of the layout of the detection device of the gauge on site;
FIG. 9 is a schematic view of a detection device of the gauge;
FIG. 10 is a schematic view of a support platform;
FIG. 11 is a schematic view of a level gauge attachment.
In the figure:
1. supporting platform 2, motor 3, speed reducer 4 and torque sensor
5. Liquid level meter connecting piece 6, angle sensor 7 and video monitor mounting bracket
8. Video monitor 9, liquid level meter 10, data processing system.
Detailed Description
The invention is described in further detail below with reference to the following figures and detailed description:
as shown in fig. 1 and fig. 2, the invention relates to a field detection method of a side-mounted liquid level meter of a tank truck,
firstly, checking that residual liquid (gas) treatment, steam purging and the like are carried out in the tank car, and sampling and analyzing; the gas analysis result meets the requirement of personnel entering; verifying whether the type, the model, the nominal pressure, the precision grade and the measuring range of the liquid level meter meet the requirements or not; checking whether parts of the liquid level meter have nondestructive deformation and dial scales are clear or not; if the liquid level meter has non-conformity items, replacing corresponding liquid level meter parts; after the test is started, the other test items of the tanker are stopped.
A. Assembling a detection device on a tank car inspection site, and inputting basic data into a data processing system; as shown in FIGS. 5 and 7, the base data includes the radius of the cylinderRDistance from the center of the floating ball of the liquid level meter to the rotating shaftLDensity of liquidρLength of the floating balllDiameter of the floating balld。
B. Setting a torque sensor, an angle sensor and a video monitor to measure synchronously and transmitting the measured data to a data processing system in real time, wherein the measured data comprises torqueM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′The device is respectively obtained by measuring a torque sensor, an angle sensor and a video monitor, and the video monitor transmits a video for recording the indication change of the liquid level meter in the measuring process to a data processing system; the motor is controlled to rotate forwards at a constant speed to drive the liquid level meter to rotate from the lowest liquid level to the highest liquid level so as to complete the torque of the upper strokeM F1The rotation angle of the floating ball of the upper stroke liquid level meterθ 1 And the indication of the upstroke liquid level meter
Measuring (2); the motor is controlled to rotate reversely at a constant speed to drive the liquid level meter to rotate from the highest liquid level to the lowest liquid level so as to complete the lower stroke torqueM F2Lower stroke liquid level meter floating ball rotation angleθ 2 And down stroke level meter reading
Measuring (2);
C. obtaining rotation angles of floating balls of different liquid level meters through simulation calculation in a data processing systemθLower float to drain off liquid volumeVThe central position of the floating ball relative to the liquid levelSA reference table of (1);
the relationship between the volume of the liquid discharged by the float ball and the height of the liquid level (the height of the liquid level and the central position of the liquid level relative to the float ball are expressed by different references, and they can be converted) is schematically shown in FIG. 6, where several liquid levels are arrangedH 1、H 2、H 3……H i… corresponding to the volume of liquid displaced by the floating ballV 1、V 2、V 3……V i…。
The floating ball model is established through computer programming simulation calculation, when the floating ball is vertically placed, the length direction of the floating ball is coincided with the vertical direction, a coordinate system is shown in figure 7, the origin of coordinates is located at the center of the floating ball, and a dimension is establishedl*d*dA cuboid circumscribed on the floating ball, wherein,lthe length of the floating ball,dthe diameter of the float ball.
The cuboid is uniformly sampled, and the coordinate of the sampling point is (x i ，y j ，z k ）；
Numerical valuenDetermining the sampling quantity, density and precision of the calculation result for the sampling density factor;
according to the diameter of the floating balldAnd lengthlDetermining a sampling point (x i ，y j ，z k ) Whether the ball is in the floating ball or not, the judged result is assigned toP ijk ；
If the sample point coordinates (x i ，y j ，z k ) Satisfy the requirement of
If the sampling point is located at the straight cylinder part of the floating ball;
if the sample point coordinates (x i ，y j ，z k ) Satisfy the requirement of
And is
，
The sampling point is located in the spherical portion of the float.
When the sampling point is located in the floating ball, the sampling point will beP ijk The value is assigned to 1; otherwiseP ijk The value is assigned to 0;
therefore, the formula for judging whether the sampling point is in the floating ball is shown as follows;
in the formula, AND is AND operation, OR is OR operation, abs is absolute value;
when the floating ball of the liquid level meter rotates by an angle ofθAt a liquid level ofHThe central position of the liquid level relative to the floating ballS=H-（R-L·cos θ) When the utility model is used, the water is discharged,Hvalue is [ R- L·cosθ-l/2，R- L·cosθ+l/2]In the interval of the time interval,
the coordinate transformation is carried out on the sampling point, the new coordinate system is translated and rotated relative to the original coordinate system, the rotating shaft of the liquid level meter is a new coordinate origin, and the rotating angle of the new coordinate system isθThe coordinates of the sampling point after the coordinate transformation are
：
When in use
Then the sampling point after coordinate transformation is positioned at the height of liquid levelHThe following;
judging whether the sampling point is in the floating ball and at the liquid levelHThe result of the judgment is assigned to
The judgment formula is as follows:
when the sampling point is in the floating ball and at the liquid levelHWhen the following, will
Assign 1, otherwise will
The value is assigned to 0;
when the rotation angle of the floating ball of the liquid level meter isθAt a liquid level ofHI.e. the central position of the liquid level relative to the floating ball isS，nWhen the value is large enough, the liquid volume discharged by the floating ballVComprises the following steps:
change the central position of the liquid level relative to the floating ballSIs measured (i.e., the value is changed)H) Calculating the current liquid level heightHTake a value in
Volume of liquid displaced by the float during intervalVThe central position of the floating ball relative to the liquid levelSThe corresponding relation of (1) is that the table output by the computer is a floating ball rotation angle of a certain liquid level meter for convenient table lookupθVolume of liquid displaced by lower floatVThe central position of the liquid level relative to the floating ballSThe comparison table (2).
Change the rotation angle of the floating ball of the liquid level meterθThe numerical value of (2) is calculated according to the steps to obtain the rotation angles of the floating balls of different liquid level metersθVolume of liquid displaced by lower floatVRelative to the center of the liquid levelSThe comparison table (2).
D. B, measuring the rotation angle of the floating ball of the liquid level meter according to the step BθTorque of the motorM FObtaining the rotation angle of the floating ball of the liquid level meter by calculating and looking up the tableθHeight of liquid levelHA reference table of (1);
rotation angle of floating ball of liquid level meterθHeight of liquid levelHThe comparison table comprises an upper stroke liquid level meter floating ball rotation angle and liquid level comparison table and a lower stroke liquid level meter floating ball rotation angle and liquid level comparison table.
According to the up stroke and the down strokeRespectively measuring the rotation angle of the floating ball of the upper stroke liquid level meterθ 1 Torque of upstrokeM F1Lower stroke liquid level meter floating ball rotation angleθ 2 Torque of down strokeM F2Upper stroke liquid level meter float ball rotation angleθ 1 And upstroke torqueM F1Lower stroke liquid level meter floating ball rotation angleθ 2 Torque of down strokeM F2The rotation angles of the floating balls of the upper stroke liquid level meter are calculated according to a formula and are in one-to-one correspondence in timeθ 1 And the rotation angle of a floating ball of the down stroke liquid level meter isθ 2 Volume of liquid actually displaced by the floatV 1 And volume of liquidV 2 (ii) a To the rotation angle of the floating ball of the upper stroke liquid level meterθ 1 And the rotation angle of a floating ball of the down stroke liquid level meter isθ 2 The calculated volume of the liquid actually discharged by the floating ballV 1 And volume of liquidV 2 Volume of liquid displaced from the float ball obtained according to step CVThe central position of the floating ball relative to the liquid levelSComparing the volume values in the comparison table, interpolating to determine the rotation angle of the floating ball of the upstroke liquid level meterθ 1 Corresponding central position of liquid level relative to the floating ballS 1 And the rotation angle of the floating ball of the down stroke liquid level meterθ 2 Corresponding central position of liquid level relative to the floating ballS 2 And further calculating to obtain the rotation angle of the floating ball of the upper stroke liquid level meterθ 1 Corresponding liquid level heightH 1 And the rotation angle of the floating ball of the down stroke liquid level meterθ 2 Corresponding liquid level heightH 2 WhereinH 1 =R-（L·cosθ 1 - S 1 ）、H 2 =R-（L·cosθ 2 -S 2 ) (ii) a C, measuring all the upper stroke liquid level meter floating ball rotation angles and upper stroke torques obtained in the step B and all the lower stroke liquid level meter floating ball rotation angles and lower stroke torques,calculating according to the steps, and outputting final results to a comparison table of the rotation angle and the liquid level height of the floating ball of the upper stroke liquid level meter and a comparison table of the rotation angle and the liquid level height of the floating ball of the lower stroke liquid level meter;
obtaining the rotation angle of the floating ball of the liquid level meterθHeight of liquid levelHThe specific procedure for the comparison table is as follows: when the rotation angle of the floating ball of the liquid level meter is measuredθWhen the corresponding torque isM FThe volume of the liquid actually discharged by the floating ball is
C, checking the volume of the liquid discharged by the floating ball obtained in the step CVThe central position of the floating ball relative to the liquid levelSWhen the floating ball is opened, the volume of the liquidVThe central position of the floating ball relative to the liquid levelSVolume in the control table of (2)ViIs equal toV(whereinV=M F/（ρ·g·L·sinθ) When the liquid level is at the central position of the floating ballSiIs the actual liquid level position or the volume of liquid displaced by the floatVThe central position of the floating ball relative to the liquid levelSVolume in the control table of (2)ViAndV(whereinV=M F/（ρ·g·L·sinθ) When approaching, the interpolation calculation obtains the central position of the liquid level relative to the floating ballSiThe central position of the liquid level relative to the floating ballSiIs the actual liquid level position; height of liquid levelH=R-（L·cosθ-Si) Thus, the rotation angle of the floating ball of the liquid level meterθHeight of liquid levelHEstablishing a corresponding relation, and calculating the rotation angles and torques of all the liquidometers obtained by the measurement in the step B according to the steps to obtain the rotation angle of the floating ball of the liquidometerθHeight of liquid levelHA reference table of (1);Sthe height position of the liquid level relative to the center of the floating ball is measured whenSWhen the pressure is negative, the liquid level is below the center of the floating ball.
E. Selecting at least five detection points; for a certain detection point J, according to the comparison table of the upper stroke liquid level meter floating ball rotation angle and liquid level height obtained in the step D and the comparison table of the lower stroke liquid level meter floating ball rotation angle and liquid level height, due to the data of the angle sensor and the videoThe data of the monitors are in one-to-one correspondence in time, so that the rotation angle of the floating ball of the liquid level meter, the reading of the liquid level meter and the actual liquid level height are in one-to-one correspondence in time, and the reading of the liquid level meter in the upper stroke is obtained by the video monitor
And down stroke level meter reading
The actual liquid level at the detection point J ishActual liquid level height of detection point JhThe numerical value of the upper stroke liquid level meter is obtained from a comparison table of the rotation angle of the floating ball of the upper stroke liquid level meter and the liquid level height and a comparison table of the rotation angle of the floating ball of the lower stroke liquid level meter and the liquid level height;
F. calculating the measurement error of each detection point
；
Calculating the return difference of each detection point
；
Wherein the content of the first and second substances,H m in order to be the measuring range of the liquid level meter,
in order to indicate the number of the upper stroke liquid level meter,
is the indication number of the liquid level meter of the downstroke,
in order to indicate the number by the liquid level meter,hthe actual liquid level height of the detection point is obtained.
G. And judging whether the liquid level meter is qualified or not. When the maximum error is satisfied
The return difference satisfies
And judging that the product is qualified, otherwise, judging that the product is unqualified.
As shown in fig. 8 to 11, a tank truck side-mounted level gauge on-site detection device is used for realizing a tank truck side-mounted level gauge on-site detection method, and comprises a supporting platform 1, a motor 2, a speed reducer 3, a torque sensor 4, a level gauge connecting piece 5, an angle sensor 6, a video monitor mounting bracket 7, a video monitor 8 and a data processing system 10; the motor 2 and the speed reducer 3 are arranged on the supporting platform 1, the combination of the motor and the speed reducer is adopted, the constant-speed rotation of the liquid level meter 9 during detection is controlled, the accuracy of detection data can be ensured, the output end of the speed reducer is connected with the torque sensor 4, and the torque sensor 4 and the angle sensor 6 are connected with the liquid level meter 9 through the liquid level meter connecting piece 5; the video monitor mounting bracket 7 is provided with a video monitor 8; the data of the torque sensor 4, the angle sensor 6 and the video monitor 8 are transmitted to a data processing system 10 through transmission lines.
The level gauge connecting piece is two U type groove structures, the circle axle in U type groove is circular hollow structure, and U type groove links to each other with the level gauge cue of being surveyed and has guaranteed the fastness of connecting, is provided with four bolt holes on the U type groove for installation locking bolt, locking bolt have the function of locking and adjusting part position concurrently, and the circle axle of level gauge connecting piece is circular hollow structure, is convenient for realize the centering with the level gauge rotation axis, and two total level gauge connecting pieces of this device, one link to each other with torque sensor, and the other links to each other with angle sensor.
The supporting platform 1 is of a tetrapod structure, the tetrapod supporting platform is portable and can adapt to a narrow space in a tank, four supporting legs of the tetrapod are divided into an upper section supporting leg and a lower section supporting leg in two mutually perpendicular directions respectively, the upper section supporting leg is of a hollow structure and is fixed on the mounting support in a threaded connection mode, and the lower section supporting leg is sleeved inside the upper section supporting leg, can move up and down and can be locked through a locking bolt, so that the adjustment is facilitated; the bottom of the lower section of supporting leg is of a spherical structure, so that the bottom of the lower section of supporting leg is in contact with the arc surface of the cylinder body, and the mounting support is provided with a plurality of bolt holes for mounting detection equipment such as a motor, a speed reducer and the like; the four support legs are distributed in two vertical directions, the included angle between the four support legs and the vertical direction is 5-20 degrees, and the length of each support leg can be adjusted, so that the support platform can be suitable for the circular arc surface structure of the cylinder body of the tank car; the landing leg can be dismantled, can adjust supporting platform's height.
Video monitor installing support 7 one end is circular clamp structure, fix on the level gauge panel board, the video monitor installing support 7 other end is circular or square or other structural style, be used for installing video monitor, video monitor can link to each other with the support through parts such as clip, be connected through three interval 120 bracing piece between clamp structure end and the installing end of video monitor, video monitor axis and level gauge panel board axis coincidence have been guaranteed, guarantee to look at the panel board well, the eye error when reducing and reading the registration.
The embodiment is as follows: firstly, checking that residual liquid (gas) treatment, steam purging and the like are carried out in the tank car, and sampling and analyzing; the gas analysis result meets the requirement of personnel entering; verifying whether the type, the model, the nominal pressure, the precision grade and the measuring range of the liquid level meter meet the requirements or not; checking whether parts of the liquid level meter have nondestructive deformation and dial scales are clear or not; if the liquid level meter has non-conformity items, replacing corresponding liquid level meter parts; after the test is started, the other test items of the tanker are stopped.
1. Assembling a detection device in the tank car, and installing equipment such as a supporting platform, a motor, a speed reducer and the like;
2. one liquid level meter connecting piece is connected with the torque sensor, and the other liquid level meter connecting piece is connected with the angle sensor;
3. installing a video monitor installing support on a display instrument of the liquid level meter, and adjusting the position of the video monitor to enable the video monitor to be in front view of the instrument;
4. connecting data transmission lines of a torque sensor, an angle sensor and a video monitor to a data processing system, wherein the torque sensor, the angle sensor and the video monitor are respectively used for measuring torqueM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′And is provided with a torque sensor and an angle sensorThe sensor and the video monitor synchronously measure and transmit the measured data to the data processing system in real time;
5. entering barrel radius in a data processing systemR(1250 mm), the distance from the center of the floating ball of the liquid level meter to the rotating shaft isL(1150 mm), liquid densityρ(516.7 kg/m3, 20 ℃) and the geometric size of the floating ball (the length of the floating ball)l=120mm, radius of floating balld=60mm）。
6. The control switch is turned on, the motor rotates forward at a constant speed to drive the liquid level meter to rotate from the lowest liquid level to the highest liquid level, and the torque of the upstroke is completedM F1Upper stroke liquid level meter floating ball rotation angleθ 1 And the indication of the upstroke liquid level meter
The data of the torque sensor and the angle sensor are transmitted to the data processing system in real time, and the video monitor transmits the video for recording the indication change of the liquid level meter to the data processing system; similarly, the motor rotates reversely at a constant speed to drive the liquid level meter to rotate from the highest liquid level to the lowest liquid level, and the lower stroke torque is completedM F2Lower stroke liquid level meter floating ball rotation angleθ 2 And down stroke level meter reading
Measuring (2);
7. obtaining rotation angles of floating balls of different liquid level meters through simulation calculation in a data processing systemθVolume of liquid displaced by lower floatVThe central position of the liquid level relative to the floating ballSThe comparison table (2).
Because the liquid level meter has a detection blind area, the rotation angle range of a floating ball of the liquid level meter to be detected is assumed to be 20-160 degrees.
Obtaining the rotation angle of a floating ball of a liquid level meterθVolume of liquid displaced by lower floatVThe central position of the liquid level relative to the floating ballSThe comparison table and the process of calculating the volume of liquid discharged by the floating ball under a certain rotation angle of the floating ball of the liquid level meter by using the Monte Carlo method are as follows:
establishing a floating ball model in a computer according to the geometric dimension of the floating ball, and establishing a cuboid with the dimension of 120 × 60mmAnd is externally tangent to the floating ball.
The cuboid is sampled evenly and the sampling is carried out,n=128, sample point coordinates
The following were used:
according to the diameter of the floating ball
And length
Judging the sampling point
Whether in the floater: to be provided with
Taking the sampling point of (1) as an example, the coordinates of the sampling point
Due to the fact that
And is made of
Then the sampling point
On the ball part of the float ball
。
When the floating ball of the liquid level meter rotates by an angleθIs 135 degrees and the height of the liquid levelH2063 mm, namely the central position of the liquid level relative to the floating ballS=2063-（1250-1150×cos135°）=-0.17 mmWhen the utility model is used, the water is discharged,
coordinates of sampling point
The coordinate transformation is carried out to carry out the coordinate transformation,
due to the fact that
Therefore, the sampling point is positioned above the liquid level,
order to
；
Judging all sampling points according to the above mode and calculating
The number of the (c) component(s),
the volume of liquid displaced by the floatVComprises the following steps:
thus obtaining the rotation angle of the floating ball of the liquid level meterθAt 135 degrees, the liquid level is opposite to the central position of the floating ballS=-0.17mmTime of flight，Volume of liquid displaced by the floatV。
According to the steps, the central position of the liquid level relative to the floating ball is changedSBy changing the level of the liquid accordinglyHWhereinS=H-（1250-1150×cos135 degree, calculateHValue in the interval
Volume of liquid displaced by the floatV，
The volume of the liquid discharged by the floating ball when the rotation angle of the floating ball of the liquid level meter is 135 degrees is obtainedVThe central position of the floating ball relative to the liquid levelSThe comparison table between.
Change the rotation angle of the floating ball of the liquid level meterθThe numerical value of (2) is calculated according to the steps, so that the rotation angles of the floating balls of different liquid level meters can be obtainedθVolume of liquid displaced by lower floatV(volume in the table)VThe unit of (a): mm is3) The central position of the liquid level relative to the floating ballSThe following are examples:
in the process of calculating the volume by the Monte Carlo method, the number of sampling points has a great influence on the calculation precision. In this embodiment, the results are shown asn=128 hours, thenAnd (4) more accurate results. The verification is as follows: when the rotation angle of the floating ball of the liquid level meter is 0 degrees and S =60mm, the floating ball is completely immersed in the liquid, the volume of the liquid discharged by the floating ball is the total volume of the floating ball, and the theoretical volume of the floating ball
Volume of liquid displaced by a floating ball obtained by the Monte Carlo methodV=282530
The error is: 0.075%, in the acceptable range, the feasibility and accuracy of the monte carlo method are verified.
For example, when the upper stroke is measured, the rotation angle of the floating ball of the upper stroke liquid level meterθ 1 Is 45 DEG and has an upstroke torqueM F1When the average molecular weight is 0.751251 N.m,
the volume of the liquid actually discharged by the floating ball is
=182447.4116 mm3
Volume of liquid displaced by the floatVRelative to the center of the liquid levelSAs can be seen from the comparison table of (A),Swhen the ratio is not less than 10,V（10）=181309.12 mm3; Swhen the number of the terminal is not less than 11,V（11）=185158.01 mm3
i.e. the actual liquid level is in-betweenS=10 andSbetween =11, from interpolation:
V 1=182447.4116 mm3when the liquid level is opposite to the central position of the floating ballS 1=10.29574451 mm，
The liquid level height is then:
H 1 =R-（L·cosθ 1 -S 1）=447.1229461mm=0.44712 m，
thus, the floating ball of the upper stroke liquid level meter in the upper stroke measuring process is obtainedAngle of rotationθ 1 At 45 deg. and liquid levelH 1 And =0.44712 m, the corresponding relation between the rotation angle of the floating ball of the liquid level meter and the height of the liquid level is obtained.
Calculating all data of the upstroke detection process according to the steps (programming and automatic calculation can be carried out in a computer), obtaining the corresponding relation between the rotation angle of the floating ball of the liquid level meter and the liquid level height within the measurement range of 20-160 degrees, and listing a comparison table 1 of the rotation angle of the floating ball of the upstroke liquid level meter and the liquid level height.
TABLE 1 COMPARATIVE TABLE OF FLOATING BALL ROTATION ANGLE (DEG) AND LIQUID LEVEL HEIGHT (mm) OF UP-STROKE LIQUID LEVEL GAUGE
And similarly, all data in the down stroke detection process can be calculated to obtain the corresponding relation between the rotation angle of the floating ball of the liquid level meter and the liquid level height in the measurement range of 20-160 degrees, and a comparison table 2 for the rotation angle of the floating ball of the down stroke liquid level meter and the liquid level height is listed.
TABLE 2 COMPARATIVE TABLE FOR FLOATING BALL ROTATION ANGLE (DEG) AND LIQUID LEVEL (mm) OF LOWER-RANGE LIQUID LEVEL GAUGE
Selecting five detection points in comparison table 1 and comparison table 2, such as 0.2m, 0.7m, 1.2m, 1.7m, and 2.3m,
the rotation angle of the upper stroke liquid level meter floating ball is obtained in the inserting value of the table 1, the rotation angle of the lower stroke liquid level meter floating ball is obtained in the inserting value of the table 2, and the results are shown in the following table 3:
TABLE 3 corresponding relationship between liquid level and rotation angles of upper and lower stroke level gauges
For the selected detection point, the actual liquid level height, the rotation angle of the floating ball of the liquid level meter and the reading of the liquid level meter are in one-to-one correspondence in time, and the reading of the upstroke liquid level meter can be obtained through the video monitor
And down stroke level meter reading
The actual liquid level at the detection point ishIn this embodiment, the actual liquid levelh0.2m, 0.7m, 1.2m, 1.7m and 2.3m respectively;
the measurement error for the selected detection point
。
The return difference of each detection point is
；
HmRead on the gauge panel.
Through the steps, the error and the return difference of each detection point are obtained;
8. and (4) judging a result: when the maximum error is satisfied
The return difference satisfies
If yes, the result is qualified.
The invention discloses a field detection method of a side-mounted liquid level meter of a tank truck, which has the following principle:
when the liquid level meter is in a static state or a constant-speed rotating state, the liquid level meter is subjected to stress analysis, and gravity is the gravity borne by the structure of the liquid level meter and acts on the gravity center. Since the gauge typically has a weight, its center of gravity is typically not on the float. The resistance is the resistance of the transmission structure at the rotating shaft and is generally represented in a resistance moment mode, and the action position and the action direction of each force are shown in figure 3.
The direction of the buoyancy is always vertical upwards, the floating ball is of an oblong structure (the middle is of a cylindrical structure, and the two ends are of hemispherical structures), and when the liquid level rises, the floating ball moves circularly around a shaft in the same plane, so that the buoyancy cannot be directly measured in the tank car due to the limitation of site conditions.
The gauge model can be simplified as follows, as shown in fig. 4. When the liquid level meter rotates at a constant speed, the following steps are performed:M o+M G=M F，
in the formula:M o: moment of resistance at the spindle;
M G: a gravitational moment;
M F: a buoyancy moment;
when the buoyancy is calculated, the distance from the center of the floating ball of the liquid level meter to the rotating shaft is taken as L, and the buoyancy force arm is
The buoyancy borne by the floating ball can be obtained
According to the Archimedes principle, the buoyancy F borne by the floating ball is equal to the weight of the liquid discharged by the floating ball, namely:
the black shaded portion in fig. 5 is the volume of liquid displaced by the float.
In fig. 5:R: tank car barrelRadius (inner diameter) in m;
L: the distance from the center of a floating ball of the liquid level meter to the rotating shaft is m;
h: the actual liquid level height is m;
θ: the angle of the floating ball is in degrees;
ρ: liquid density in kg/m3；
because the floating ball is of an oblong structure (the middle is of a cylinder structure, and the two ends are of hemispheres), the floating ball is always in an inclined position in the rotation process of the liquid level meter, and when the floating ball is in a certain rotation angle, although the volume of liquid discharged by the floating ball can be obtained through torqueVBut volume of liquid displaced by the floatVAnd the height of the liquid surfaceHThe corresponding relation between the floating balls can change along with the change of the rotation angle of the floating ball, the angle of the floating ball changes, the shape of the floating ball below the liquid level continuously changes, and the liquid level height cannot be obtained through derivation by an analytic methodHThen the bottom of the interface between the liquid level and the floating ball can not be obtainedH 1、H 2Or alsoH 3Referring to fig. 6, a general-purpose computer program cannot be programmed, and a liquid level meter detection device cannot be developed.
The invention provides a method for determining the relation between the volume of liquid drained by a floating ball and the central position of a liquid level relative to the floating ball by a simulation calculation method, and comparing the relation with the volume obtained by calculating the torque to determine the position of the liquid level so as to determine the height of the liquid level.
It should be noted that the protection scope of the present invention is not limited to the above specific examples, and the object of the present invention can be achieved by substantially the same structure according to the basic technical concept of the present invention, and embodiments that can be imagined by those skilled in the art without creative efforts belong to the protection scope of the present invention.
Claims (6)
1. The field detection method of the side-mounted liquid level meter of the tank truck is characterized by comprising the following steps
A. Entering basic data in a data processing system, including cylinder radiusRDistance from the center of the floating ball of the liquid level meter to the rotating shaftLDensity of liquidρLength of the floating balllDiameter of the float balld；
B. The motor drives the liquid level meter to rotate at a constant speed to complete torqueM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′Synchronous measurement; torque ofM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′Measured by a torque sensor, an angle sensor and a video monitor respectively, and the measured torqueM FRotation angle of floating ball of liquid level meterθAnd the indication of the liquid level meterh′Transmitting the data to a data processing system in real time;
C. obtaining rotation angles of floating balls of different liquid level meters through simulation calculation in a data processing systemθLower float to drain off liquid volumeVThe central position of the floating ball relative to the liquid levelSA reference table of (1);
D. b, measuring the rotation angle of the floating ball of the liquid level meter according to the step BθTorque of the motorM FObtaining the rotation angle of the floating ball of the liquid level meter by calculating and looking up the tableθHeight of liquid levelHA reference table of (1);
E. selecting at least five detection points; for a certain detection point J, looking up the data of the video monitor to obtain the indication number of the liquid level meterh′The actual liquid level at the detection point J ish；
F. Calculating the error of the liquid level meter at each detection point
Return difference of liquid level meter
；
G. And (3) judging whether the liquid level meter is qualified: when the maximum error is satisfied
2. The on-site detection method of a tank car side-loading level gauge according to claim 1,
in the step B, the uniform rotation of the motor comprises forward uniform rotation of the motor and reverse uniform rotation of the motor;
when the motor rotates forwards at a constant speed, the liquid level meter is driven to rotate from the lowest liquid level to the highest liquid level, and the torque of the upper stroke is completedM F1Upper stroke liquid level meter floating ball rotation angleθ 1 And the indication of the upstroke liquid level meter
Measuring (2); when the motor rotates reversely at a constant speed, the liquid level meter is driven to rotate from the highest liquid level to the lowest liquid level, and the lower stroke torque is completedM F2Lower stroke liquid level meter floating ball rotation angleθ 2 And down stroke level meter reading
Measuring (2);
step C, establishing a floating ball model, wherein the length of the floating ball islThe diameter of the floating ball isd，The length direction of the floating ball is coincided with the vertical direction, and the origin of the coordinate system is positioned at the center of the floating ball; establishing a dimension ofl*d*dA cuboid circumscribed to the floating ball;
uniformly sampling the cuboid, wherein the number and density of sampling pointsDegree depends onnThe coordinates of the sampling point arex i ，y j ，z k ）；
According to the diameter of the floating balldAnd lengthlDetermining a sampling point (x i ，y j ，z k ) Whether the ball is in the floating ball or not, the judged result is assigned toP ijk ；
When the sampling point is located in the floating ball, the sampling point will beP ijk The value is assigned to 1; otherwise it will beP ijk The value is assigned to 0;
when the floating ball of the liquid level meter rotates by an angle ofθAt a liquid level ofHThe central position of the liquid level relative to the floating ballS=H-（R-L·cosθ) When the utility model is used, the water is discharged,Hvalue is inR- L·cosθ-l/2，R- L·cosθ+l/2]In the interval of the time interval,
to the coordinates of the sampling point: (x i ，y j ，z k ) Performing coordinate transformation to obtain transformed coordinates
；
When in use
Then the sampling point after coordinate transformation is positioned at the height of liquid levelHThe following;
judging whether the sampling point is in the floating ball and at the liquid levelHThe result of the judgment is assigned to
The judgment formula is as follows:
when the sampling point is in the floating ball and at the liquid levelHWhen the following, will
The value is 1, otherwise the value is 0;
volume of liquid displaced by the floatV： 
Wherein n is a sampling density factor;
obtain the rotation angle of the floating ball of the liquid level meter asθThe central position of the liquid level relative to the floating ball isSVolume of liquid displaced by the floatV(ii) a Changing the value of the central position S of the liquid level relative to the floating ball, calculating according to the steps, and outputting the result as the rotation angle of the floating ball of a certain liquid level meterθVolume of liquid displaced by lower floatVThe central position of the floating ball relative to the liquid levelSA reference table of (1); change the rotation angle of the floating ball of the liquid level meterθCalculating according to the steps to obtain the rotation angles of the floating balls of the different liquid level metersθLower float to drain off liquid volumeVThe central position of the floating ball relative to the liquid levelSA reference table of (1);
step D, rotating angle of a floating ball of the liquid level meterθHeight of liquid levelHThe comparison table comprises an upper stroke liquid level meter floating ball rotation angle and liquid level comparison table and a lower stroke liquid level meter floating ball rotation angle and liquid level comparison table;
the rotation angle of the floating ball of the upstroke liquid level meter is respectively measured according to the upstroke and the downstrokeθ 1 Torque of upstrokeM F1Lower stroke liquid level meter floating ball rotation angleθ 2 Torque of down strokeM F2And the rotation angle of the floating ball of the upper stroke liquid level meter is obtained by calculationθ 1 And the rotation angle of a floating ball of the down stroke liquid level meter isθ 2 Volume of liquid actually displaced by the floatV 1 And volume of liquidV 2 (ii) a The calculated volume of the liquid actually discharged by the floating ballV 1 And volume of liquidV 2 And the volume of the liquid discharged by the floating ball obtained by simulation according to the step CVThe central position of the floating ball relative to the liquid levelSControlThe volume values in the meter are compared and subjected to interpolation calculation to determine the central position of the liquid level relative to the floating ball, and then the rotating angle of the floating ball of the upper stroke liquid level meter is calculatedθ 1 Corresponding liquid level heightH 1 And the rotation angle of the floating ball of the down stroke liquid level meterθ 2 Corresponding liquid level heightH 2 The output is a comparison table of the rotation angle and the liquid level height of the floating ball of the upper stroke liquid level meter and a comparison table of the rotation angle and the liquid level height of the floating ball of the lower stroke liquid level meter;
step E, the liquid level meter displaysh′Including the indication of upstroke level meter
And down stroke level meter reading
Checking the data of the video monitor according to the comparison table of the upper stroke rotation angle and the liquid level height and the comparison table of the lower stroke rotation angle and the liquid level height obtained in the step D to obtain the indication number of the upper stroke liquid level meter corresponding to the detection point J
And down stroke level meter reading
The actual liquid level at the detection point J ishActual liquid level height of detection point JhThe numerical value of the upper stroke liquid level meter is obtained from a comparison table of the rotation angle of the floating ball of the upper stroke liquid level meter and the liquid level height and a comparison table of the rotation angle of the floating ball of the lower stroke liquid level meter and the liquid level height;
step F, error of the liquid level meter at each detection point
Return difference of liquid level meter at each detection point
；
Wherein the content of the first and second substances,H m in order to be the measuring range of the liquid level meter,
in order to indicate the number of the upper stroke liquid level meter,
is the indication number of the liquid level meter of the downstroke,h′in order to indicate the number by the liquid level meter,hthe actual liquid level height of the detection point is obtained.
3. A field detection device of a side-mounted liquid level meter of a car tank is used for realizing the field detection method of the side-mounted liquid level meter of the car tank as claimed in claim 1, and is characterized by comprising a supporting platform (1), a motor (2), a speed reducer (3), a torque sensor (4), a liquid level meter connecting piece (5), an angle sensor (6), a video monitor mounting bracket (7), a video monitor (8) and a data processing system (10); the motor (2) and the speed reducer (3) are arranged on the supporting platform (1), the output end of the speed reducer is connected with the torque sensor (4), and the torque sensor (4) and the angle sensor (6) are connected with the liquid level meter (9) through the liquid level meter connecting piece (5); a video monitor (8) is arranged on the video monitor mounting bracket (7); and the data of the torque sensor (4), the angle sensor (6) and the video monitor (8) are transmitted to a data processing system (10) through transmission lines.
4. The on-site detection device for the tank car side-mounted liquid level meter according to claim 3, wherein the liquid level meter connecting piece is a double U-shaped groove, a round shaft of the U-shaped groove is of a round hollow structure, and the U-shaped groove is connected with a floating ball rod of the liquid level meter of the detected piece.
5. The on-site detection device for the tank truck side-mounted liquid level meter according to claim 3, wherein the supporting platform (1) is of a tetrapod structure, four support legs of the tetrapod are respectively arranged in two mutually perpendicular directions, an included angle between the four support legs and the vertical direction is 5-20 degrees, the four support legs are divided into an upper support leg and a lower support leg, and the bottom of the lower support leg is of a spherical structure.
6. The on-site detection device for the tank truck side-mounted liquid level meter of the claim 3, characterized in that one end of the video monitor mounting bracket (7) is in a circular hoop structure and fixed on the instrument panel of the liquid level meter, the other end of the video monitor mounting bracket (7) is in a circular or square shape and used for mounting a video monitor, and the axis of the video monitor is coincident with the axis of the instrument panel of the liquid level meter; the video monitor is fixed right above the liquid level meter through the mounting bracket.
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