Patent Application
20240019536
This application is based on and claims priority under 35 U.S.C. Section 119 to Japanese Patent Application No. 2022-114142 filed on Jul. 15, 2022, the entire content of which are incorporated herein by reference.
This disclosure relates to a distance sensor module.
JPH05-52622A discloses as a distance sensor module a water surface sensor configured to use an ultrasonic wave to detect the surface of water in a water channel in a non-contact manner.
JP2015-10403A discloses as a distance sensor module a water level sensor disposed on the reverse face (lower face) of the body of a cover of a manhole and connected to a wireless communication controller through a connection cable.
JP2017-207400A discloses as a distance sensor module a water gauge including a light source and a light position detector of a non-contact type. The light source includes a light-emitting diode configured to emit a light beam toward a water surface. The light position detector includes a position sensitive detector configured to receive a light beam as reflected by a water surface to detect the position of the light reception.
A distance sensor module may be simply disposed, as disclosed in JP2015-10403A, on the lower face of a cover of a manhole to detect the surface of water flowing through a pipe.
Distance sensor modules for measuring the level of water in a pipe are classified into a contact type and a non-contact type, depending on the method of measurement. Distance sensor modules of the contact type include those of a float type, a guide rope type, a pressure type as disclosed in JP2015-10403A, an electrical capacitance type, and a differential pressure type. Distance sensor modules of the non-contact type include those of an electric wave type, an ultrasonic wave type as disclosed in JPH05-52622A, and an optical type as disclosed in JP2017-207400A.
Distance sensor modules of the contact type are relatively inexpensive, but may be deformed or damaged through contact with an object in water or become incapable of normal measurement due to adhesion of an object. Further, a distance sensor module of the contact type, when installed or maintained, needs to have its sensor in water flowing through the pipe. The maintenance requires a lot of time and effort, possibly necessitating draining water and adjusting the zero point each time, and needs to be performed at a short cycle.
Distance sensor modules of the non-contact type, on the other hand, are not deformed or damaged and may be maintained easily, as opposed to the contact type. On the down side, a distance sensor module of the non-contact type needs adjustment to keep a predetermined angle to the water surface. A distance sensor module of the non-contact type needs to be oriented with high accuracy if, for instance, the distance sensor module is intended to emit a detection signal vertically downward, that is, in a direction at an angle of 90 degrees to the water surface.
In view of the above issue, a distance sensor module of the non-contact type will require distance calculation based on an intended angle if the distance sensor module is (i) configured to emit an ultrasonic wave or a light beam as a detection signal (as in JPH05-52622A or JP2017-207400A) toward a water surface and detect the detection signal as reflected by the water surface to measure the distance between the distance sensor module and the water surface and (ii) intended to emit the detection signal in a direction at an angle other than 90 degrees to the water surface.
As described above, a distance sensor module configured to detect a water surface with use of a detection signal needs to emit the detection signal vertically downward to facilitate the measurement and keep high measurement performance. None of JPH05-52622A, JP2015-10403A, and JP2017-207400A discloses orienting a distance sensor module to improve measurement accuracy.
Managing a pipe may involve opening and closing a cover of the manhole. If, for instance, the cover has been closed in a tilted or otherwise inappropriate orientation, the distance sensor module on the lower face of the cover is also inappropriately oriented. This may lead to the distance sensor module inaccurately measuring the position of a water surface.
Such a concern arises not only when the measurement target is water, but also when it is a fluid other than water or a solid.
The above circumstances have led to a demand for a distance sensor module capable of accurately measuring the distance between the distance sensor module and a measurement target even in an inappropriate orientation.
A distance sensor module according to this disclosure includes: a distance sensor; and a housing, the distance sensor including: a sensor body; and a transmission and reception section connected to the sensor body and configured to emit a detection signal toward a measurement target and receive the detection signal as reflected by the measurement target, the distance sensor being of a non-contact type such that the sensor body is configured to measure a distance between the distance sensor and the measurement target as a result of the transmission and reception section receiving the detection signal, the housing including: a sensor container section containing the distance sensor; and an attachment section configured to attach the sensor container section to an external attachment target, the sensor container section being configured to keep the transmission and reception section so oriented due to gravity as to have a vertically downward detection direction with the attachment section attached to the attachment target.
The above configuration keeps the transmission and reception section so oriented due to gravity as to have a vertically downward detection direction with the housing attached to the attachment target with use of the attachment section. This allows the distance sensor to keep an appropriate orientation relative to a measurement target even if the attachment target has changed its orientation. The distance sensor module is thus capable of accurately measuring the distance between the distance sensor module and a measurement target even in an inappropriate orientation.
The distance sensor module may be further configured such that the transmission and reception section faces the measurement target, and the distance sensor has a center of gravity on a central axis of the transmission and reception section.
Orienting the distance sensor so that its center of gravity is on the central axis of the transmission and reception section allows the distance sensor to emit a detection signal vertically downward due to gravity.
The distance sensor module may be further configured such that the sensor container section contains the distance sensor in such a manner that allows the distance sensor to change an orientation within a predetermined space.
With the above configuration, the distance sensor is capable of changing its orientation only within a predetermined space, and does not come into contact with the inner surface of the housing.
The distance sensor module may be further configured such that the sensor container section has a lower end protruding downward by such an amount that when the distance sensor has changed an orientation within a predetermined space, no portion of the distance sensor protrudes downward from the lower end in a side view.
With the above configuration, when the distance sensor has been tilted maximally, no portion of the distance sensor protrudes downward from the lower end of the sensor container section in a side view. The sensor container section thereby protects the distance sensor against breakage when the distance sensor module is on the lower face of a manhole cover and has received an impact from the cover due to its weight such as when the cover has been dropped onto the ground by mistake.
The distance sensor module may further include: a restrictor configured to limit a change of an orientation of the distance sensor relative to the sensor container section.
The restrictor prevents the distance sensor in the sensor container section from changing its orientation beyond the limits.
The distance sensor module may further include: a fixing member configured to fix the distance sensor in such a manner as to prevent the distance sensor from changing an orientation.
The fixing member prevents the distance sensor in the sensor container section from changing its orientation, and thereby prevents the distance sensor from coming into strong contact with the inner surface of the housing due to vibration or the like.
The distance sensor module may be further configured such that the distance sensor is contained in the sensor container section in such a manner as to be capable of swinging to change an orientation relative to the housing, a first one of the distance sensor and the housing includes a swing axis section, whereas a second one of the distance sensor and the housing includes a swing support holding the swing axis section, and that one of the swing axis section and the swing support which the distance sensor includes has a center vertically upward of a center of gravity of the distance sensor.
With the above configuration, when the housing becomes oriented inappropriately, the distance sensor is swung about the swing axis section with the swing axis section held by the swing support. This allows that one of the swing axis section and the swing support which the distance sensor includes to have a center vertically upward of the center of gravity of the distance sensor. This in turn allows the distance sensor to emit a detection signal vertically downward.
The distance sensor module may be further configured such that the housing includes the swing axis section at the attachment section whereas the distance sensor includes the swing support, the swing axis section protrudes upward and has a gradually smaller diameter toward an upper end thereof, and the swing support is a depressed surface section open downward and in contact with the upper end of the swing axis section.
The swing axis section extends upward and has a gradually smaller diameter toward its upper end, whereas the swing support is a depressed surface section open downward and in contact with the upper end of the swing axis section. This allows the distance sensor to be suspended at the position of the contact as a holding point and thereby to emit a detection signal vertically downward.
The distance sensor module may be further configured such that the distance sensor includes the swing axis section whereas the housing includes the swing support at the attachment section, the swing axis section protrudes downward and has a gradually smaller diameter toward a lower end thereof, and the swing support is a depressed surface section open upward and in contact with the lower end of the swing axis section.
The swing axis section extends downward and has a gradually smaller diameter toward its lower end, whereas the swing support is a depressed surface section open upward and in contact with the lower end of the swing axis section. This allows the distance sensor to be suspended at the position of the contact as a holding point and thereby to emit a detection signal vertically downward.
The distance sensor module may further include: a cushion disposed in contact with the housing and the distance sensor and configured to prevent vibration of the attachment section from being transmitted to the distance sensor.
The cushion absorbs vibration transmitted from the attachment section of the housing and thereby prevents vibration of the distance sensor for high-accuracy measurement.
The distance sensor module may further include: a cushion disposed in contact with the housing and the distance sensor and surrounding the swing axis section.
With the above configuration, the cushion absorbs vibration regardless of the direction in which the distance sensor is vibrated relative to the housing, and also prevents dust from entering the space in which the swing axis section is disposed.
The distance sensor module may be further configured such that the distance sensor is a millimeter-wave radar sensor that uses a millimeter wave as the detection signal, and the distance sensor includes a portion covering the transmission and reception section which portion is made of an insulator.
The insulator protects the outer face of the transmission and reception section. Further, the distance sensor is a millimeter-wave radar sensor that uses a millimeter wave as the detection signal. The distance sensor is thus capable of measuring the distance between the distance sensor and a measurement target without being affected by the environment as compared to a distance sensor that uses a light beam.
Another distance sensor module according to this disclosure includes: a distance sensor; and a housing, the distance sensor including: a sensor body; and a transmission and reception section connected to the sensor body and configured to emit a detection signal toward a measurement target and receive the detection signal as reflected by the measurement target, the distance sensor being of a non-contact type such that the sensor body is configured to measure a distance between the distance sensor and the measurement target as a result of the transmission and reception section receiving the detection signal, the housing including: a sensor container section containing the distance sensor; an attachment section configured to attach the sensor container section to an external attachment target; and a holder mechanism holding a portion of the distance sensor which portion is opposite to the transmission and reception section in such a manner that the distance sensor is suspended from the housing and capable of changing an orientation, the sensor container section being configured to keep the transmission and reception section so oriented due to gravity as to have a vertically downward detection direction with the attachment section attached to the attachment target.
The above distance sensor module is configured such that with the housing held with use of the attachment section, the holder mechanism holds a portion of the distance sensor which portion is opposite to the transmission and reception section in such a manner that the distance sensor is suspended from the housing and capable of changing its orientation. This allows the distance sensor to keep so oriented due to gravity that the transmission and reception section faces vertically downward. The distance sensor module is thus capable of accurately measuring the distance between the distance sensor module and a measurement target even in an inappropriate orientation.
The description below deals with an embodiment of this disclosure with reference to drawings.
The distance sensor S is of a non-contact type and includes a transmission and reception section 12 (see
As illustrated in
The distance sensor module A is used in combination with a communication unit 4 disposed on the lower face of the cover 3. The communication unit 4 contains a battery (not illustrated in the drawings) and is configured to (i) receive from the distance sensor module A information on the distance between the distance sensor S and the water surface f as detected by the distance sensor module A and (ii) transmit the distance information wirelessly to a server or the like for managing the pipe 1.
The distance sensor module A is used in the orientation illustrated in
The distance sensor module A includes an orientation keeper V, and is configured such that the distance sensor S (specifically, its sensor body 10) is suspended from the housing H with use of the orientation keeper V. This allows the distance sensor module A to keep so oriented that the transmission and reception section 12 emits a detection signal vertically downward from its transmission and reception face 12S. The orientation keeper V, as illustrated in
As illustrated in
The distance sensor S does not necessarily have a square shape in a plan view, and may alternatively have a shape such as a circular or polygonal shape. The distance sensor S may, even if not having a square shape in a plan view, include a body wall 10a and holder shafts 14 protruding horizontally from the body wall 10a, similarly to the structure illustrated in drawings such as
The cross-sectional views such as
The sensor body 10 contains a sensor control circuit (not illustrated in the drawings) configured to control the transmission and reception section 12 to receive distance information and transmit the distance information to the communication unit 4.
The transmission and reception section 12 is in the form of a millimeter-wave radar configured to emit a millimeter wave as a detection signal from the distal end face of the protrusion 11 and receive the millimeter wave as reflected by a water surface f to measure the distance between the distance sensor S and the water surface f. The transmission and reception section 12, which uses a millimeter wave as a detection signal, is capable of the measurement even with the transmission and reception face 12S covered by resin, as the detection signal passes through the resin.
The sensor body 10 has a center of gravity W substantially at the center in a plan view, under which the transmission and reception section 12 is disposed. Thus, when the distance sensor module A is oriented as illustrated in
The sensor body 10 may be configured such that the transmission and reception section 12 is on the weight line WL or at the center of gravity W of the sensor body 10 to allow the transmission and reception section 12 to have a vertically downward detection direction.
As illustrated in
In the case where the distance sensor S has a circular shape in a plan view, the distance sensor S includes a body wall 10a circular in a plan view and holder shafts 14 protruding horizontally from the circular wall. In the case where the distance sensor S has a polygonal shape in a plan view, the distance sensor S includes a body wall 10a polygonal in a plan view and holder shafts 14 protruding horizontally from the respective sides of the polygon. If the distance sensor S has a shape other than a circular or polygonal shape in a plan view, the distance sensor S includes a body wall 10a shaped accordingly and holder shafts 14 protruding horizontally from the outer surface of the body wall 10a.
The four holder shafts 14 each have a circular cross-sectional shape. Each pair of opposite holder shafts 14 are coaxial with each other.
As illustrated in
The distance sensor S is provided with a holder plate 15 apart from and above the top wall 13 of the sensor body 10. The holder plate 15 includes a plate body 15a, four arms 15b, and four protrusions 15c. The plate body 15a is parallel to the top wall 13. The arms 15b extend outward from the outer edge of the plate body 15a. The protrusions 15c protrude from the respective distal ends of the arms 15b downward along the vertical Z axis.
The protrusions 15c each have a hole open upward. The distance sensor S is provided with four screws 16 disposed through the respective holes and screwed in the sensor body 10 to couple the holder plate 15 to the distance sensor S. As illustrated in
As illustrated in
The housing H includes a top wall 20, a vertical wall 21, and an attachment section 22. The top wall 20 has a square (rectangular) shape in a plan view. The vertical wall 21 extends downward from the outer edge of the top wall 20. The attachment section 22 is a flange extending outward from the outer edge of the top wall 20. The top wall 20, the vertical wall 21, and the attachment section 22 are integrally made of resin.
As illustrated in
The top wall 20 has a recess with a flat bottom wall 20a at a central portion in a plan view. The housing H includes an axial member 23 (swing axis section VA) integral with the bottom wall 20a and disposed at the center of the bottom wall 20a in a plan view. The axial member 23 protrudes upward and has a gradually smaller diameter toward the upper end. The bottom wall 20a has four through holes 20b around the axial member 23. The axial member 23 is in the form of a tapered rotor rotatable about a vertical axis.
The four vertical wall portions 21a each have a vertical slit 21b at the center along the width. The slits 21b receive the respective holder shafts 14 of the sensor body 10 with the distance sensor module A as assembled. The distance sensor module A is configured such that the vertical wall 21 protrudes downward by such an amount that when the distance sensor S has been tilted maximally, no portion of the distance sensor S protrudes downward from the lower end of the vertical wall 21 (that is, the lower end of the sensor container section Hs) in a side view (that is, as viewed perpendicularly to the vertical Z axis). With this configuration, the vertical wall 21 protects the distance sensor S when the cover 3 of the manhole 2 has given a strong impact due to its weight to the distance sensor module A on the cover 3 such as when the cover 3 has been dropped onto the ground by mistake.
As illustrated in
The orientation keeper V is configured such that the axial member 23 has an upper end in contact with the depressed surface section 15S of the holder plate 15 at the swing center so that the distance sensor S is suspended from the housing H in a stable orientation. The axial member 23 having an upper end in contact with the depressed surface section 15S at a holding point P as above allows the distance sensor S to swing about the holding point P (swing center) relative to the housing H. When the housing H is horizontal as illustrated in
The orientation keeper V is configured as follows: If the housing H, which is normally horizontal as illustrated in
As illustrated in
The restrictor arms 24 each have a base end hole 24a at its base end, and are each provided with a swing holder shaft 25 in the form of a screw disposed through the corresponding base end hole 24a and fixed to the corresponding vertical wall portion 21a. This allows each restrictor arm 24 to be held by the corresponding swing holder shaft 25 in such a manner as to be swingable about the swing holder shaft 25. The restrictor arms 24 each have a curved elongated hole 24b at an intermediate portion, and are each provided with a restrictor shaft 26 in the form of a screw disposed through the corresponding elongated hole 24b and fixed to the corresponding vertical wall portion 21a. This defines limits on the swing of each restrictor arm 24. The restrictor arms 24 each have, near the elongated hole 24b, a cooperation hole 24c through which the corresponding holder shaft 14 is disposed. This allows each restrictor arm 24 to swing about the corresponding swing holder shaft 25 in response to a vertical movement of the corresponding holder shaft 14.
The restrictor R for the present embodiment is configured not such that the restrictor arms 24 illustrated in drawings such as
The restrictor arms 24 may each be fastened to the corresponding vertical wall portion 21a with use of the corresponding restrictor shaft 26 in such a manner as to be incapable of swinging, in which case the restrictor shaft 26 serves as a fixing member. The fixing members prevent the respective restrictor arms 24 from swinging, and thereby prevent the distance sensor S from changing its orientation. The restrictor R may use as fixing members a pair of screws or pins disposed through each elongated hole 24b or members in contact with respective outer faces of the distance sensor S to define the swing limits.
When the distance sensor S is horizontal, the two holder shafts 14 for which the restrictor arms 24 are provided are each at a basic position illustrated in
The above configuration allows each restrictor arm 24 to (i) swing about the corresponding swing holder shaft 25 in response to the distance sensor S swinging relative to the housing H and (ii) stop its swing in response to the corresponding restrictor shaft 26 coming into contact with a longitudinal end of the corresponding elongated hole 24b. This defines limits on the swing of the distance sensor S.
As illustrated in
The distance sensor module A is configured such that the cushion 17 lessens, for example, external vibration or impact on the distance sensor S. The cushion 17 absorbs vibration of the distance sensor S to allow the distance sensor S to return to and stop in the horizontal orientation earlier. This prevents inaccurate sensing by the distance sensor S. The cushion 17 also prevents dust from entering the space between the tapered portion of the axial member 23 and the depressed surface section 15S of the holder plate 15.
The distance sensor module A is configured such that the attachment section 22 of the housing H is screwed or otherwise fixed to the lower face of a cover 3 of a manhole 2. Fixing the distance sensor module A to the lower face of a cover 3 as such allows the distance sensor module A to keep its weight line WL vertical due to gravity, the weight line WL extending through the center of gravity W and the transmission and reception section 12. When the cover 3 is horizontal with the distance sensor module A fixed as above, the orientation keeper V, as illustrated in
When, for instance, the cover 3 becomes tilted or otherwise oriented inappropriately as illustrated in
The distance sensor module A may be disposed on a bridge or in a facility on a river terrace or the like for measurement of the water level of a river. In such cases, while the surface on which the distance sensor module A is disposed such as a horizontal iron pole may become inclined over time, the distance sensor module A allows the distance sensor S to swing due to its self weight and remain horizontal. The distance sensor module A may be attached to the back face of the cover of a septic tank or the ceiling of the tank for measurement of the level of water in the tank. The distance sensor module A is also usable for measurement of the level of water in a paddy field or a hydroponic field.
The distance sensor module A is configured in particular such that the distance sensor S remains inside the sensor container section Hs even if the distance sensor S has changed its orientation relative to the housing H. The restrictor arms 24 limit how much the distance sensor S changes its orientation relative to the housing H, and thereby prevent the distance sensor S from greatly changing its orientation relative to the housing H and coming into unintended contact with the inner surface of the vertical wall 21.
The distance sensor module A is configured such that the vertical wall 21 protrudes downward by such an amount that when the distance sensor S has been tilted maximally, no portion of the distance sensor S protrudes downward from the lower end of the vertical wall 21 (that is, the lower end of the sensor container section Hs) in a side view (that is, as viewed perpendicularly to the vertical Z axis). With this configuration, the vertical wall 21 protects the distance sensor S when the cover 3 of the manhole 2 has given a strong impact due to its weight to the distance sensor module A on the cover 3 such as when the cover 3 has been dropped onto the ground by mistake.
The distance sensor module A includes a cushion 17 configured to prevent the distance sensor S from being greatly moved relative to the housing H as a result of the distance sensor module A vibrating due to, for instance, external vibration or impact. This prevents erroneous measurement.
The plate body 15a includes at a lower face thereof a depressed surface section 15S (swing support VS) open downward, that is, in the direction in which gravity acts. This lets a water droplet or dust on a portion of contact between the axial member 23 and the depressed surface section 15S drop therefrom due to gravity, and thereby allows the distance sensor S to reliably swing inside the sensor container section Hs of the housing H.
This disclosure may be configured as below in addition to the embodiments described above. Any element described below that functions as described for the embodiments above is assigned with the same reference numeral as that for embodiments above.
(a) The distance sensor module A may, as illustrated in
Alternative embodiment (a) is configured such that the axial body 18 has a tapered end and that the depressed section 27 has a V-shaped cross section, that is, a deep central portion, and is in the form of a rotor rotatable about the weight line WL of the distance sensor S. This allows the axial body 18 to have a lower end in contact with the deepest portion of the depressed section 27 due to gravity on the distance sensor S, the contact portion being a holding point P.
Alternative embodiment (a) is compared to the embodiment described above under “Description of Embodiments” (hereinafter referred to as “first embodiment”) as follows: The axial body 18 and the depressed section 27 (corresponding to the depressed surface section 15S for the first embodiment) are upside down in comparison to their corresponding elements. Alternative embodiment (a) allows the distance sensor S to be suspended from the housing H with use of the orientation keeper V, similarly to the first embodiment.
Alternative embodiment (a) is similar in configuration to the first embodiment in that it includes a cushion 17 made of a material such as rubber or flexibly deformable resin and sandwiched between the lower face of the holder plate 15 and the upper face of the bottom wall 20a. Alternative embodiment (a) is similar to the first embodiment in that it includes a pair of restrictor arms 24.
(b) The distance sensor module A may, as illustrated in
Alternative embodiment (b) is configured such that the housing H does not include an element corresponding to the bottom wall 20a for the first embodiment. Alternative embodiment (b) includes an upper holder 31 and a lower holder 32. The upper holder 31 protrudes downward from the center of the lower face of the flat top wall 20. The lower holder 32 is at the center of the top wall 13.
The upper holder 31 has a lower end portion in the form of a cylinder open downward. The lower holder 32 has an upper end portion in the form of a cylinder open upward. The coil spring 30 has an upper end fitted in the cylindrical portion of the upper holder 31 and a lower end fitted in the cylindrical portion of the lower holder 32.
Alternative embodiment (b) is configured such that the distance sensor S is suspended from the housing H with use of the coil spring 30. This allows the distance sensor S to keep its weight line WL vertical regardless of how the housing H is oriented.
(c) Alternative embodiment (b) may be modified such that the holder mechanism T is not a coil spring 30 but a synthetic fiber string or a flexibly deformable wire.
(d) The distance sensor S may be configured to use as the detection signal an ultrasonic wave or a light beam such as of infrared radiation or visible radiation.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022-114142 | Jul 2022 | JP | national |
