Bin Zhang

This research put forward an exogenous liquid level measurement method based on continuous sound wave amplitude. The distribution of round piston transducers in the sound field of a metal solid was analyzed by building 15 Multi-Gaussian Beam superposition models; the calculation method for echo sound pressure was worked out according to the reflection and refraction properties of ultrasonic wave. The continuous wave with three amplitudes was used as the driving source of ultrasonic sensor, and two single-crystal sensors with the same diameter were used as the transmitting terminal and receiving terminal of ultrasonic waves to carry out experiments for four groups of containers of different wall thickness and to compare the characteristics of echo energy of driving sources with three amplitudes above and below the liquid levels with different wall thickness. Two groups of sensors of different diameters were used to measure the liquid levels of experimental models, and the measuring errors of the two groups of sensors were analyzed and compared. The experimental result shows that the measuring error of the model is less than 5 mm, so it is applicable to the level measurement of liquids or liquid mixtures in many sectors.

By simulating the sound field of a round piston transducer with the Kirchhoff integral theorem and analyzing the shape of ultrasound beams and propagation characteristics in a metal container wall, this study presents a model for calculating the echo sound pressure by using the Kirchhoff paraxial approximation theory, based on which and according to different ultrasonic impedance between gas and liquid media, a method for detecting the liquid level from outside of sealed containers is proposed. Then, the proposed method is evaluated through two groups of experiments. In the first group, three kinds of liquid media with different ultrasonic impedance are used as detected objects; the echo sound pressure is calculated by using the proposed model under conditions of four sets of different wall thicknesses. The changing characteristics of the echo sound pressure in the entire detection process are analyzed, and the effects of different ultrasonic impedance of liquids on the echo sound pressure are compared. In the second group, taking water as an example, two transducers with different radii are selected to measure the liquid level under four sets of wall thickness. Combining with sound field characteristics, the influence of different size transducers on the pressure calculation and detection resolution are discussed and analyzed. Finally, the experimental results indicate that measurement uncertainly is better than ±5 mm, which meets the industrial inspection requirements.

This study presents a novel method for determining the liquid level from the outside of a sealed container, which is based on the balance of echo energy received by two receiving sensors. The proposed method uses one transmitting transducer and two receiving sensors that are encapsulated in a coupling plane and arranged by certain rules. The calculation and comparison of echo energy are grounded on the difference ultrasonic impedance between gas and liquid media. First, by analyzing the propagation and attenuation characteristics of ultrasonic waves in a solid, an acoustic model for calculating the echo energy is established and simulated in MATLAB. Second, the proposed method is evaluated through a series of experiments. The difference and ratio of echo energy received by two receiving sensors are calculated and compared under two different coupling conditions. Two kinds of the sensors that are arranged by different rules are selected for measuring the liquid level, and the measurement are analyzed and discussed in detail. Finally, the experimental results indicate that the proposed method can meet the proposed accuracy requirements and can effectively solve the problems caused by some poor coupling conditions.

The proposed method for measuring the liquid level focuses on the ultrasonic impedance and echo energy inside a metal wall, to which the sensor is attached directly, not on ultrasonic waves that penetrate the gas–liquid medium of a container. Firstly, by analyzing the sound field distribution characteristics of the sensor in a metal wall, this paper proposes the concept of an "energy circle" and discusses how to calculate echo energy under three different states in detail. Meanwhile, an ultrasonic transmitting and receiving circuit is designed to convert the echo energy inside the energy circle into its equivalent electric power. Secondly, in order to find the two critical states of the energy circle in the process of liquid level detection, a program is designed to help with calculating two critical positions automatically. Finally, the proposed method is evaluated through a series of experiments, and the experimental results indicate that the proposed method is effective and accurate in calibration of the liquid level outside a sealed metal container.

The main limitation of high-temperature piezoresistive pressure sensors is the variation of output voltage with operating temperature, which seriously reduces their measurement accuracy. This paper presents a passive resistor temperature compensation technique whose parameters are calculated using differential equations. Unlike traditional experiential arithmetic, the differential equations are independent of the parameter deviation among the piezoresistors of the microelectromechanical pressure sensor and the residual stress caused by the fabrication process or a mismatch in the thermal expansion coefficients. The differential equations are solved using calibration data from uncompensated high-temperature piezoresistive pressure sensors. Tests conducted on the calibrated equipment at various temperatures and pressures show that the passive resistor temperature compensation produces a remarkable effect. Additionally, a high-temperature signal-conditioning circuit is used to improve the output sensitivity of the sensor, which can be reduced by the temperature compensation. Compared to traditional experiential arithmetic, the proposed passive resistor temperature compensation technique exhibits less temperature drift and is expected to be highly applicable for pressure measurements in harsh environments with large temperature variations.

This paper focuses on the design and fabrication of a high-temperature piezoresistive pressure sensor with an integrated signal-conditioning circuit, which consists of an encapsulated pressure-sensitive chip, a temperature compensation circuit and a signal-conditioning circuit. A silicon on insulation (SOI) material and a standard MEMS process are used in the pressure-sensitive chip fabrication, and high-temperature electronic components are adopted in the temperature-compensation and signal-conditioning circuits. The entire pressure sensor achieves a hermetic seal and can be operated long-term in the range of −50 °C to 220 °C. Unlike traditional pressure sensor output voltage ranges (in the dozens to hundreds of millivolts), the output voltage of this sensor is from 0 V to 5 V, which can significantly improve the signal-to-noise ratio and measurement accuracy in practical applications of long-term transmission based on experimental verification. Furthermore, because this flexible sensor’s output voltage is adjustable, general follow-up pressure transmitter devices for voltage converters need not be used, which greatly reduces the cost of the test system. Thus, the proposed high-temperature piezoresistive pressure sensor with an integrated signal-conditioning circuit is expected to be highly applicable to pressure measurements in harsh environments.