CN115468624B - Continuous high-temperature liquid metal liquid level sensor and preparation method of sensitive core thereof - Google Patents
Continuous high-temperature liquid metal liquid level sensor and preparation method of sensitive core thereof Download PDFInfo
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- CN115468624B CN115468624B CN202211151555.7A CN202211151555A CN115468624B CN 115468624 B CN115468624 B CN 115468624B CN 202211151555 A CN202211151555 A CN 202211151555A CN 115468624 B CN115468624 B CN 115468624B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/80—Arrangements for signal processing
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/80—Arrangements for signal processing
- G01F23/802—Particular electronic circuits for digital processing equipment
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- G—PHYSICS
- G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
- G21C—NUCLEAR REACTORS
- G21C17/00—Monitoring; Testing ; Maintaining
- G21C17/02—Devices or arrangements for monitoring coolant or moderator
- G21C17/035—Moderator- or coolant-level detecting devices
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E30/00—Energy generation of nuclear origin
- Y02E30/30—Nuclear fission reactors
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Abstract
The invention discloses a continuous high-temperature liquid metal liquid level sensor and a preparation method of a sensitive core body thereof, belongs to the technical field of sensor manufacturing, and aims to solve the problem that the insulation resistance of a wire is easy to decrease in a high-temperature environment of the existing liquid metal liquid level sensor, so that the resolution of the sensor is affected. It comprises the following steps: the sensitive core body is packaged in a cavity of the stainless steel shell, and an end cover and a high-temperature tube seat are respectively arranged at two ends of the stainless steel shell; the sensitive core body comprises a soft magnetic alloy iron core, an alumina skeleton and a sensitive coil; the alumina skeleton is of a cylindrical structure; the sensitive coil comprises an excitation coil and an induction coil, the excitation coil and the induction coil are circumferentially coiled on the alumina skeleton in a double-line parallel winding mode, and a soft magnetic alloy iron core is inserted into a cavity in the alumina skeleton; the liquid level sensor is inserted into the blind pipe, the blind pipe is immersed into the metal liquid to be detected, the exciting coil generates induced eddy current in the metal liquid to be detected, and the induction coil outputs induced voltage. For level measurement of high temperature liquid metal.
Description
Technical Field
The invention relates to a liquid metal liquid level sensor, and belongs to the technical field of sensor manufacturing.
Background
Sodium-cooled fast reactor is the most developed and mature reactor type of 6 fourth generation advanced nuclear reactors published by the fourth Generation International Forum (GIF) of nuclear energy systems. Sodium-cooled fast reactors receive attention from all countries of the world because of their inherent safety, the advantages of being able to proliferate nuclear fuels, transmutation and long-life radioactive waste, and the like. Due to the strict requirements of space systems on factors such as power level volume, quality, safety and the like, the metallic sodium cold fast neutron reactor becomes the only power source of a 50-400kW space power supply, and the application research of the space miniature nuclear reactor power system is actively carried out in all the aerospace countries of the world. The sodium-cooled fast reactor is used in sea water desalination, regional heat supply, ship power, space power and other fields, and becomes a hot spot for research in many developed countries, and is used for equipment of deep space exploration in the 21 st century, conventional nuclear submarines, other nuclear power devices, commercial nuclear power plants and the like.
Sodium is used as a heat carrier in liquid metal reactors and experimental facilities, wherein a large amount of liquid sodium surface exists, and the liquid level of the liquid sodium surface needs to be monitored. Each gas/liquid interface in the primary and secondary loops and auxiliary systems of the reactor needs accurate and reliable liquid level measurement so as to ensure the normal operation of the reactor and the heat transfer system, determine whether the container overflows or not, and judge whether sodium leakage exists or not. Because sodium reacts with many substances, it is usually completely sealed in a stainless steel container, so its level measurement method must use a sensor sealed inside a stainless steel sleeve to give a reading remotely. Since the temperature of the metal coolant is usually controlled to 500 c when in the liquid state, it is required that the operating temperature of the level sensor must be able to withstand temperatures up to 500 c, and the measurement can range from tens of millimeters to more than a few meters, which varies considerably.
The traditional electromagnetic induction type liquid metal liquid level sensor adopts two core wires in a double-core armored cable with stainless steel as a cladding and magnesium oxide as an insulating layer as an excitation winding and an output winding which are respectively wound on an iron core along the circumferential direction, the working temperature of the sensor is limited by the core wires, the temperature rise directly leads to insulation resistance between winding coils to be reduced, and the resolution of the sensor is influenced or even the measurement is invalid.
Disclosure of Invention
The invention aims to solve the problem that the insulation resistance of a lead is easy to decrease in a high-temperature environment of the existing liquid metal liquid level sensor, so that the resolution of the sensor is affected, and provides a continuous high-temperature liquid metal liquid level sensor and a preparation method of a sensitive core of the continuous high-temperature liquid metal liquid level sensor.
The invention provides a continuous high-temperature liquid metal liquid level sensor, which comprises an end cover, a stainless steel shell, a sensitive core body and a high Wen Guan;
the sensitive core body is packaged in a cavity of the stainless steel shell, and an end cover and a high-temperature tube seat are respectively arranged at two ends of the stainless steel shell;
the sensitive core body comprises a soft magnetic alloy iron core, an alumina skeleton and a sensitive coil; the alumina skeleton is of a cylindrical structure;
the sensitive coil comprises an excitation coil and an induction coil, the excitation coil and the induction coil are circumferentially coiled on the alumina skeleton in a double-line parallel winding mode, and a soft magnetic alloy iron core is inserted into a cavity in the alumina skeleton;
the liquid level sensor is inserted into a blind pipe with one sealed end, the blind pipe is immersed into the metal liquid to be detected, the exciting coil generates induced eddy current in the metal liquid to be detected, and the induction coil outputs induced voltage.
Preferably, the alumina skeleton comprises a ceramic substrate, a metal wiring layer and an insulating ceramic layer;
printing a metal wiring layer on the outer Zhou Siwang of the ceramic substrate; the periphery of the ceramic substrate is laminated with an insulating ceramic layer, and the insulating ceramic layer is provided with a signal leading-out hole.
Preferably, the sensitive coil is a spiral coil with double-line parallel winding structure manufactured by adopting a circumferential printing process and is manufactured by adopting silver-platinum sizing agent.
Preferably, the metal wiring layer is a silver-platinum paste wiring layer.
Preferably, the signal extraction holes are filled with silver-platinum slurry.
The invention provides a preparation method of a sensitive core of a continuous high-temperature liquid metal liquid level sensor, which comprises the following specific processes:
s1, cutting a casting film piece into a ceramic substrate and an insulating ceramic layer;
s2, punching a signal lead-out hole in the insulating ceramic layer;
s3, screen printing a metal wiring layer on the ceramic substrate;
s4, carrying out via hole metallization treatment on the signal leading-out holes obtained in the step S2;
s5, laminating the ceramic substrate and the insulating ceramic to prepare a substrate, rotationally attaching the substrate and the ceramic rod by adopting a rotary tool, and cutting off redundant parts to prepare a substrate green body of the sensitive core;
s6, placing the substrate green body into a glue discharging furnace, and setting a glue discharging system according to the thickness of the substrate green body and a thermogravimetric analysis curve to prepare a glue-discharged substrate green body;
s7, placing the substrate blank subjected to glue discharge into a chain type sintering furnace, and sintering at a high temperature of 1200 ℃ to prepare a substrate;
and S8, printing silver-platinum sizing agent on the surface of the substrate in a double-line parallel winding mode through circumferential screen printing, and then placing the substrate in a chain type sintering furnace for sintering at a high temperature of 850 ℃ to prepare the sensitive core body.
Preferably, S8 the silver-platinum paste is printed on the surface of the substrate in a double-line parallel winding mode, and the pitch of the double lines is as follows: one third of the liquid level accuracy.
The invention has the advantages that: the continuous high-temperature liquid metal liquid level sensor and the preparation method of the sensitive core thereof provided by the invention are characterized in that a double-line parallel-winding spiral-wound three-dimensional sensitive core is prepared on a soft magnetic iron core by combining a circumferential screen printing technology with a high-temperature co-sintering ceramic process technology, one group of coils are used as exciting coils, the other group of coils are used as induction coils which change along with the liquid level, and the phenomenon that the lead is easy to break due to overlong external leads is avoided by printing a wiring layer inside the core. The sensitive core body is sintered at high temperature, so that the use temperature is higher, the insulation resistance of the wire is prevented from being reduced due to high temperature of the winding coil, and the volume and the weight of the liquid level sensor are further reduced.
The continuous high-temperature liquid metal liquid level sensor and the preparation method of the sensitive core thereof adopt the electromagnetic induction principle to measure the liquid level signal of the metal coolant in a non-contact way, and the liquid level range of the measured liquid metal is larger and is 1500mm. The change of the liquid level can be measured in a high-temperature environment, and the maximum measurement temperature can reach 500 ℃.
Drawings
FIG. 1 is a schematic diagram of a continuous high temperature liquid metal level sensor according to the present invention;
FIG. 2 is a schematic structural view of a sensitive core according to the present invention;
FIG. 3 is a cross-sectional view of an alumina framework according to the present invention;
FIG. 4 is a schematic diagram of a mutual inductance type liquid level test based on eddy current loss;
fig. 5 is a schematic block diagram of the signal detection of the continuous high temperature liquid metal level sensor of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other.
The invention is further described below with reference to the drawings and specific examples, which are not intended to be limiting.
Example 1:
the following describes the present embodiment with reference to fig. 1 to 3, and the continuous high temperature liquid metal level sensor according to the present embodiment includes an end cap 1, a stainless steel housing 2, a sensitive core 3, and a height Wen Guan;
the sensitive core body 3 is packaged in a cavity of the stainless steel shell 2, and the end cover 1 and the high Wen Guan 4 are respectively arranged at two ends of the stainless steel shell 2;
the sensitive core body 3 comprises a soft magnetic alloy iron core 3-1, an alumina framework 3-2 and a sensitive coil 3-3; the alumina skeleton 3-2 is a cylindrical structure;
the sensitive coil 3-3 comprises an excitation coil 3-3-1 and an induction coil 3-3-2, the excitation coil 3-3-1 and the induction coil 3-3-2 are circumferentially coiled on the alumina skeleton 3-2 in a double-line parallel winding mode, and a soft magnetic alloy iron core 3-1 is inserted into a cavity in the alumina skeleton 3-2;
the liquid level sensor is inserted into a blind pipe with one sealed end, the blind pipe is immersed into the metal liquid to be detected, the exciting coil 3-3-1 generates induced eddy current in the metal liquid to be detected, and the induction coil 3-3-2 outputs induction voltage.
Further, the alumina skeleton 3-2 comprises a ceramic substrate 3-2-1, a metal wiring layer 3-2-2 and an insulating ceramic layer 3-2-3;
printing a metal wiring layer 3-2-2 on the outer Zhou Siwang of the ceramic substrate 3-2-1; the periphery of the ceramic substrate 3-2-1 is laminated with an insulating ceramic layer 3-2-3, and the insulating ceramic layer 3-2-3 is provided with a signal leading-out hole 3-2-4.
In this embodiment, the metal routing layer 3-2-2 functions to guide the leads of the exciting coil 3-3-1 and the induction coil 3-3-2 from the liquid zero position to the full-scale liquid level end. The wires are all hidden in the core body, so that overlong lead tearing and breakage caused by the influence of severe environments such as vibration impact are avoided, and the reliability of the sensor is improved.
Still further, the sensitive coil 3-3 is made into a double-wire parallel-wound spiral coil by adopting a circumferential printing process, and is made of silver-platinum sizing agent.
Still further, the metal routing layer 3-2-2 is a silver-platinum paste routing layer.
Still further, the signal leading-out holes 3-2-4 are filled with silver-platinum slurry.
Example 2:
the following describes a method for preparing a sensitive core of the continuous high-temperature liquid metal level sensor according to the present embodiment with reference to fig. 1 to 3, where the specific process of the method for preparing a sensitive core includes:
s1, cutting a casting film piece into a ceramic substrate 3-2-1 and an insulating ceramic layer 3-2-3;
s2, punching signal lead-out holes 3-2-4 in the insulating ceramic layer 3-2-3;
s3, screen printing a metal wiring layer 3-2-2 on the ceramic substrate 3-2-1;
s4, carrying out via metallization treatment on the signal leading-out holes 3-2-4 obtained in the S2;
s5, stacking the ceramic substrate 3-2-1 and the insulating ceramic layer 3-2-3 together to prepare a substrate, rotationally attaching the substrate and the ceramic rod by adopting a rotary tool, and cutting off redundant parts to prepare a substrate green body of the sensitive core body 3;
s6, placing the substrate green body into a glue discharging furnace, and setting a glue discharging system according to the thickness of the substrate green body and a thermogravimetric analysis curve to prepare a glue-discharged substrate green body;
s7, placing the substrate blank subjected to glue discharge into a chain type sintering furnace, and sintering at a high temperature of 1200 ℃ to prepare a substrate;
and S8, printing silver-platinum sizing agent on the surface of the substrate in a double-line parallel winding mode through circumferential screen printing, and then placing the substrate in a chain type sintering furnace for sintering at a high temperature of 850 ℃ to prepare the sensitive core body.
Further, S8, printing the silver-platinum paste on the surface of the substrate in a form of double-line parallel winding, wherein the pitch of the double-line is as follows: one third of the liquid level accuracy.
In this embodiment, the length of the printed core and the pitch of the double-set coil are determined according to the range and the precision of the measured liquid level, the measured liquid level range of the liquid metal is larger, the precision of screen printing is higher (micron level), and in order to reduce the input impedance, the pitch is not easy to be too small during design, and 1/3 of the liquid level precision is selected.
In this embodiment, in order to prevent cracking, warping, and other phenomena of the sintered sensitive core, the alumina ceramic powder needs to be doped during the casting of the ceramic substrate, so that the shrinkage rate and the thermal expansion coefficient of the substrate ceramic and the metal layer are matched.
The working principle of the invention is described below with reference to fig. 1-5:
in use, the sensor is inserted into a stainless steel blind tube (phi 18 mm) sealed at one end, and the blind tube is immersed in liquid sodium metal.
As shown in FIG. 4, when the sensor is powered on and is completely above the liquid level, a sinusoidal AC excitation voltage with a certain frequency is applied to the excitation winding A (excitation coil 3-3-1)The induced electromotive force generated by the excitation winding a at this time in the output winding B (the induction coil 3-3-2) is referred to as a primary induced electromotive force, which can be expressed approximately as:
wherein: m represents the mutual inductance of the output winding; ω represents the angular frequency of the excitation signal; r is R 2 Representing the resistance of the output winding; l (L) 2 Representing the inductance of the output winding.
When the liquid metal level rises, the induced electromotive force of the output winding B generated by the eddy current in the liquid metal conductor is called a secondary induced electromotive force, and the total electromotive force in the output winding B is the superposition of the primary and secondary induced electromotive forces, and the total electromotive force on the output winding B without considering the eddy current loss is expressed as:
as the excitation winding is submerged by sodium metal, induced eddy currents are generated in the sodium, the magnetic field formed by the induced eddy current places causes the mutual inductance of the output winding to decrease, magnetic field disturbance and the like near the free surface of the liquid metal are ignored regardless of eddy current and hysteresis loss in the iron core, the induced voltage in the output winding linearly decreases along with the increase of the liquid level of the sodium metal, and the total electromotive force output can be expressed as:
wherein: n (N) 1 、N 2 Indicating the number of turns of the excitation winding and the output winding; mu (mu) 0 Indicating vacuum permeability; mu (mu) r Representing the relative permeability of the core; r represents a winding radius; l represents the length of the winding;representing the excitation winding current; />Representing induced eddy currents in the liquid metal.
Since the strength of the eddy current in the liquid metal can be expressed as:
wherein: k represents the submerged height of the sensor; h represents a constant.
Thus, at the excitation currentUnder the condition of stable frequency and constant current, the following qualitative relationship exists:
wherein: A. b represents the coefficient of variation with the temperature of the medium being measured.
Thus, there is a linear relationship between the output voltage of the liquid metal level sensor and the liquid level.
The detection of the sensor adopts an induction signal detection processing circuit (shown in figure 5) with mature technology, the output voltage which changes along with the liquid level is filtered and amplified and then enters an MCU microprocessor, and then the output voltage is converted into a standard current signal and a digital signal RS485MODBUS protocol to be output according to the requirement, and the on-site liquid level display can be realized through a liquid crystal screen. When the sensor actually works, the liquid level measurement value is determined by the output voltage changing along with the liquid level and the temperature of the measured medium, and according to the actual demand of a user side, the MCU microprocessor reserves a temperature compensation port for compensating the straight cylinder working medium temperature signal of the communicating vessel, the working medium temperature signal of the measured vessel and the working medium pressure signal in the measured vessel.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. It should be understood that the different dependent claims and the features described herein may be combined in ways other than as described in the original claims. It is also to be understood that features described in connection with separate embodiments may be used in other described embodiments.
Claims (5)
1. The continuous high-temperature liquid metal liquid level sensor is characterized by comprising an end cover (1), a stainless steel shell (2), a sensitive core body (3) and a high-temperature tube seat (4);
the sensitive core body (3) is packaged in a cavity of the stainless steel shell (2), and an end cover (1) and a high-temperature tube seat (4) are respectively arranged at two ends of the stainless steel shell (2);
the sensitive core body (3) comprises a soft magnetic alloy iron core (3-1), an alumina skeleton (3-2) and a sensitive coil (3-3); the alumina skeleton (3-2) is of a cylindrical structure;
the sensitive coil (3-3) comprises an exciting coil (3-3-1) and an induction coil (3-3-2), the exciting coil (3-3-1) and the induction coil (3-3-2) are circumferentially coiled on an alumina skeleton (3-2) in a double-wire parallel winding mode, and a soft magnetic alloy iron core (3-1) is inserted into an inner cavity of the alumina skeleton (3-2);
the liquid level sensor is inserted into a blind pipe with one sealed end, the blind pipe is immersed into metal liquid to be detected, an exciting coil (3-3-1) generates induced eddy current in the metal liquid to be detected, and an induction coil (3-3-2) outputs induction voltage;
the aluminum oxide framework (3-2) comprises a ceramic substrate (3-2-1), a metal wiring layer (3-2-2) and an insulating ceramic layer (3-2-3);
printing a metal wiring layer (3-2-2) on the outer Zhou Siwang of the ceramic substrate (3-2-1); an insulating ceramic layer (3-2-3) is laminated on the periphery of the ceramic substrate (3-2-1), and a signal leading-out hole (3-2-4) is formed in the insulating ceramic layer (3-2-3);
the sensitive coil (3-3) is made into a spiral coil with a double-line parallel winding structure by adopting a circumferential screen printing process and is made of silver-platinum sizing agent.
2. The continuous high temperature liquid metal level sensor of claim 1, wherein the metal routing layer (3-2-2) is a silver platinum paste routing layer.
3. The continuous high temperature liquid metal level sensor of claim 2, wherein the signal extraction holes (3-2-4) are filled with silver-platinum paste.
4. The preparation method of the sensitive core body of the continuous high-temperature liquid metal liquid level sensor is realized based on the continuous high-temperature liquid metal liquid level sensor as claimed in claim 3, and is characterized in that the specific process of the preparation method of the sensitive core body (3) comprises the following steps:
s1, cutting a casting film piece into a ceramic substrate (3-2-1) and an insulating ceramic layer (3-2-3);
s2, punching a signal lead-out hole (3-2-4) in the insulating ceramic layer (3-2-3);
s3, screen printing a metal wiring layer (3-2-2) on the ceramic substrate (3-2-1);
s4, carrying out via hole metallization treatment on the signal leading-out holes (3-2-4) obtained in the S2;
s5, stacking the ceramic substrate (3-2-1) and the insulating ceramic layer (3-2-3) together to prepare a substrate, rotationally attaching the substrate and the ceramic rod by adopting a rotary tool, and cutting off redundant parts to prepare a substrate green body of the sensitive core body (3);
s6, placing the substrate green body into a glue discharging furnace, and setting a glue discharging system according to the thickness of the substrate green body and a thermogravimetric analysis curve to prepare a glue-discharged substrate green body;
s7, placing the substrate blank subjected to glue discharge into a chain type sintering furnace, and sintering at a high temperature of 1200 ℃ to prepare a substrate;
and S8, printing silver-platinum sizing agent on the surface of the substrate in a double-line parallel winding mode through circumferential screen printing, and then placing the substrate in a chain type sintering furnace for sintering at a high temperature of 850 ℃ to prepare the sensitive core body (3).
5. The method for preparing a sensitive core of a continuous high temperature liquid metal level sensor according to claim 4, wherein S8 is a method of printing silver-platinum paste on a substrate surface in a form of double-line parallel winding, and the pitch of the double-line is as follows: one third of the liquid level accuracy.
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