Plasma ever-burning ignition control system

Abstract

The invention discloses a plasma ever-burning ignition control system which is composed of a communication module, an ignition execution module, a power supply control module and a monitoring module. Through the real-time monitoring module and the analysis module, the purpose of reducing tempering easily caused by an existing plasma torch during ignition is achieved, the tempering phenomenon can be solved in time after tempering occurs, the use risk is reduced, the collaboration among the system modules is good, and the safety of the system is improved. The communication module, the ignition execution module, the power supply control module and the monitoring module are clear in labor division and closely cooperate, communication modes are diversified, internal efficient interaction and remote monitoring management can be achieved, power supply control is accurate, voltage can be stably adjusted, parameters can be monitored and analyzed in real time, and it is guaranteed that plasma is stably generated and ignition is successful.

Description

Technical Field

[0001] The invention relates to the field of plasma, in particular to a plasma long-lasting ignition control system. Background Art

[0002] At present, plasma torches are prone to flashback risks during ignition. During the ignition process, if the operation is improper or the system design is unreasonable, flashback may occur, that is, the flame propagates backward into the plasma generator or fuel supply system, causing an explosion safety accident.

[0003] The flashback phenomenon is caused by uneven gas flow rate, large pressure fluctuations, uneven gas mixing, or abnormal electrode state. After the flashback phenomenon occurs, the flame cannot be controlled in time, causing greater losses. Therefore, there is an urgent need for a plasma continuous ignition control system that can effectively reduce flashback and control the flame. Summary of the invention

[0004] In order to solve the above-mentioned technical problems, the present invention provides a plasma long-lasting ignition control system.

[0005] The technical solution of the present invention is achieved in this way:

[0006] A plasma permanent ignition control system, consisting of a communication module, an ignition execution module, a power control module and a monitoring module;

[0007] The communication module and the microcontroller perform data transmission through an internal communication bus to establish information and instruction interaction between various modules;

[0008] The ignition execution module, when the monitoring module confirms that the status of each device is normal, the power control module starts to increase the voltage to the value required for ignition and forms a stable plasma discharge, the system triggers the ignition operation;

[0009] The power control module system monitors the output current and voltage feedback signal of the high-voltage power supply in real time to ensure that the voltage rise process is smooth and conforms to the preset curve. If the voltage rise is abnormal, such as too fast or too slow, the microcontroller adjusts the soft start parameters or checks whether the high-voltage power supply has a fault;

[0010] The monitoring module collects real-time data from various sensors, including voltage and current monitoring of electricity, flow and pressure parameter monitoring of gas, and real-time information of flames through temperature signals and image recognition units.

[0011] Preferably, it also includes an analysis module, which analyzes the device information and external information from the power control module and the monitoring module, and finally makes a status judgment on whether ignition can be performed.

[0012] Preferably, the communication module transmits the system's operating status, equipment status, ignition progress, and equipment failure information in real time to external equipment and a central control system via Ethernet and wireless communications for remote monitoring and management; receives information from the monitoring module and the power control module through communications established via an internal communication bus, and establishes a table to record historical information; and then feeds the information back to the analysis module, which then feeds the information back to an external device or an ignition execution module after a preset ignition time.

[0013] Preferably, the power control module includes a dynamic voltage adjustment unit and a real-time parameter monitoring unit;

[0014] The dynamic voltage adjustment unit drives the high voltage power supply to smoothly transition from a standby state, which is usually a lower voltage value, such as zero or a lower standby voltage, to a working state, which is achieved by a timer and a pulse width modulation (PWM) module in a digital signal processor (DSP) or a microcontroller;

[0015] The real-time parameter monitoring unit continuously communicates with the built-in feedback circuit of the high-voltage power supply to obtain the output voltage and current data of the high-voltage power supply in real time, and uses these real-time data to calculate the resistance and power parameters of the plasma to determine the generation of plasma.

[0016] Preferably, the ignition execution module also includes an instruction receiving unit, which has the ability to identify instructions from multiple sources, including remote start signals from the central control system, manual instructions from the local control panel, and instructions automatically triggered based on a preset time program, and mark and classify instructions from different sources to facilitate subsequent targeted processing based on instruction characteristics.

[0017] Preferably, the monitoring module collects real-time information of the flame through the temperature signal and the image recognition unit, monitors the flame through the ultraviolet sensor and the visible light sensor, and also monitors the flame temperature through the temperature sensor;

[0018] The monitoring module monitors the flow and pressure parameters of the gas, including gas flow rate monitoring, and installs pressure sensors at the gas supply position of the pipeline and the position inside the burner to monitor the pressure distribution of the gas.

[0019] Preferably, the analysis module also includes a judgment unit, which presets thresholds for various flame parameters, including range thresholds. When the threshold is not exceeded, the parameter is judged to be normal, and when the threshold is exceeded, the parameter is judged to be abnormal. An upper limit threshold is set, and a parameter value between the range threshold and the upper limit threshold is marked as an adjustable parameter abnormality. When the parameter value exceeds the upper limit threshold, a shutdown signal is sent to each module; and the adjustable parameter abnormality is limited to the voltage and current parameters of the power control module.

[0020] Preferably, the analysis module further includes a flashback monitoring unit for performing analysis based on parameters fed back by the monitoring module.

[0021] The present invention achieves the purpose of reducing the flashback easily caused by the current plasma torch during ignition through the real-time monitoring module and the analysis module, and can promptly solve the flashback phenomenon after the flashback occurs, thereby reducing the risk of use. The system modules of the present invention have good synergy, and the modules of communication, ignition execution, power supply control, and monitoring have clear division of labor and close cooperation. The communication methods are diverse, and internal efficient interaction and remote monitoring and management are possible. The power supply control is precise, and the voltage can be stably adjusted. The parameters can be monitored and analyzed in real time to ensure the stable generation of plasma and successful ignition. The monitoring means are rich, and the flame and gas parameters can be monitored in multiple dimensions by multiple sensors. Precise analysis and judgment can be made according to preset thresholds to ensure that the system state is normal and the flashback monitoring is effective. Detailed flashback judgment thresholds are set for multiple parameters, and the abnormality of flashback can be discovered in time and measures can be taken. The fault warning is timely, and equipment damage and safety accidents can be avoided, thereby achieving efficient, stable, and safe ignition operation as a whole. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of a plasma permanent ignition control system of the present invention. DETAILED DESCRIPTION

[0023] In order to further explain the technical means and effects taken by the present invention to achieve the predetermined invention purpose, exemplary embodiments will be described in detail here, and examples thereof are shown in the accompanying drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application. Instead, they are only examples of methods and systems consistent with some aspects of the present application as detailed in the attached claims.

[0024] The terms used in this application are for the purpose of describing specific embodiments only and are not intended to limit the present application. The singular forms "a", "the", and "the" used in this application and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0025] Example 1

[0026] The present invention provides a plasma long-lasting ignition control system, which is composed of a communication module, an ignition execution module, a power supply control module and a monitoring module;

[0027] The communication module and the microcontroller perform data transmission through an internal communication bus to establish information and instruction interaction between various modules;

[0028] The ignition execution module, when the monitoring module confirms that the status of each device is normal, the power control module starts to increase the voltage to the value required for ignition and forms a stable plasma discharge, the system triggers the ignition operation;

[0029] The power control module system monitors the output current and voltage feedback signal of the high-voltage power supply in real time to ensure that the voltage rise process is smooth and conforms to the preset curve. If the voltage rise is abnormal, such as too fast or too slow, the microcontroller adjusts the soft start parameters or checks whether the high-voltage power supply has a fault;

[0030] The monitoring module collects real-time data from various sensors, including voltage and current monitoring of electricity, flow and pressure parameter monitoring of gas, and real-time information of flames through temperature signals and image recognition units.

[0031] Preferably, it also includes an analysis module, which analyzes the device information and external information from the power control module and the monitoring module, and finally makes a status judgment on whether ignition can be performed.

[0032] Preferably, the communication module transmits the system's operating status, such as equipment status, ignition progress, and fault information, in real time to external equipment and a central control system through Ethernet and wireless communication for remote monitoring and management; receives information from the monitoring module and the power control module through communication established through an internal communication bus, and establishes a table to record historical information; and then feeds back the information to the analysis module, which then feeds back the information to an external device or an ignition execution module after a preset ignition time.

[0033] Preferably, the power control module includes a dynamic voltage adjustment unit and a real-time parameter monitoring unit;

[0034] The dynamic voltage adjustment unit drives the high-voltage power supply to smoothly transition from the standby state, which is usually a lower voltage value, such as zero or a lower standby voltage, to the working state, which is achieved through a timer and pulse width modulation (PWM) module in a digital signal processor (DSP) or a microcontroller; monitors the output current and voltage feedback signals of the high-voltage power supply in real time, obtains these real-time data by communicating with the feedback circuit built into the high-voltage power supply, and compares them with a preset soft start curve, which is a trajectory of voltage increase over time under ideal conditions, and it takes into account the characteristics of the high-voltage power supply and the system's requirements for smooth start. If the monitored voltage or current feedback signal deviates greatly from the soft start curve, such as the voltage rises too fast or too slow, it is determined to be a soft start abnormality, and corresponding corrective measures are taken immediately;

[0035] The real-time parameter monitoring unit continuously communicates with the built-in feedback circuit of the high-voltage power supply to obtain the output voltage and current data of the high-voltage power supply in real time, and uses these real-time data to calculate the resistance and power parameters of the plasma (according to Ohm's law and power calculation formula) to determine the generation of plasma.

[0036] Preferably, the ignition execution module also includes an instruction receiving unit, which has the ability to identify instructions from multiple sources, including remote start signals from the central control system, manual instructions from the local control panel, and instructions automatically triggered based on a preset time program, and mark and classify instructions from different sources to facilitate subsequent targeted processing based on instruction characteristics.

[0037] Preferably, the monitoring module collects real-time information of the flame through the temperature signal and the image recognition unit, monitors the flame through the ultraviolet sensor and the visible light sensor, and also monitors the flame temperature through the temperature sensor;

[0038] Using ultraviolet sensors to monitor, flames emit ultraviolet light when burning. Ultraviolet sensors can detect ultraviolet radiation in a specific wavelength range (usually 185-260nm). When a flame is present, the ultraviolet sensitive element in the sensor (such as a photodiode) will receive ultraviolet photons and generate a photocurrent. By monitoring the size and changes of the photocurrent, the state of the flame can be determined. When monitoring flashback, if the photocurrent suddenly increases and exceeds the fluctuation range during normal combustion, it may mean that the flame is abnormal. For example, flashback causes the flame to propagate in the opposite direction, causing the sensor to receive stronger ultraviolet radiation.

[0039] When monitoring with a visible light sensor, the flame will emit visible light, and a visible light sensor (such as a phototransistor or CCD image sensor) can detect the characteristics of the flame's brightness, color, and flickering frequency. The phototransistor can generate corresponding current changes based on the intensity of the received visible light, while the CCD image sensor can obtain image information of the flame, including the shape, size, and color distribution of the flame. When monitoring flashback, the visible light sensor can determine whether flashback has occurred by detecting the sudden increase in the brightness of the flame (possibly because the flashback brings the flame closer to the sensor), color changes (such as the color becoming redder or yellower, which may indicate incomplete combustion and flashback), and the characteristics of disordered flickering frequency;

[0040] The flame temperature is monitored using a temperature sensor. Temperature sensors (such as thermocouples and thermistors) are installed in the combustion area (such as near the flame of the plasma torch, inside the burner) and at one end of the fuel supply pipeline close to the burner to monitor the temperature of these areas in real time.

[0041] During normal combustion, the temperature of the combustion area is relatively stable and within a certain range, and the temperature at different locations also has its normal distribution pattern. When flashback occurs, the reverse propagation of the flame will cause the temperature of the combustion area to change. For example, the temperature of the combustion area may suddenly rise (because the reverse propagation of the flame makes the high-temperature part that was originally far away from the combustion area closer to the sensor, or the flame re-ignites some unburned fuel during the reverse propagation process, generating additional heat). By monitoring the temperature data fed back by the temperature sensor, if it is found that the temperature exceeds the fluctuation range during normal combustion and continues to rise, it can be preliminarily determined that flashback has occurred.

[0042] The monitoring module monitors the flow and pressure parameters of the gas, including gas flow rate monitoring, installing pressure sensors at the gas supply position of the pipeline and the position inside the burner to monitor the pressure distribution of the gas. Flow rate sensors (such as differential pressure flowmeters and hot wire anemometers) are installed at key positions of the gas supply pipeline (such as the fuel gas supply pipeline and the combustion gas supply pipeline) and the connecting pipeline between the plasma generation area and the combustion area to monitor the flow rate of the gas in real time; under normal combustion conditions, the pressure in different areas is relatively stable. When flashback occurs, the reverse propagation of the flame will cause a sudden change in gas pressure. For example, there may be a local pressure increase near the starting point of the reverse propagation of the flame (because the propagation of the flame will squeeze the surrounding gas), while there may be a pressure decrease in other areas (because the gas is pushed in the reverse direction by the flame, resulting in a reduction in the amount of gas in some areas). Through the analysis of the gas pressure monitoring data, if a sudden change in pressure that does not conform to the normal combustion law is found, it can be used as a prompt that flashback may occur.

[0043] Preferably, the analysis module also includes a judgment unit, which presets thresholds for various flame parameters, including range thresholds. When the threshold is not exceeded, the parameter is judged to be normal, and when the threshold is exceeded, the parameter is judged to be abnormal. An upper limit threshold is set, and a parameter value between the range threshold and the upper limit threshold is marked as an adjustable parameter abnormality. When the parameter value exceeds the upper limit threshold, a shutdown signal is sent to each module; and the adjustable parameter abnormality is limited to the voltage and current parameters of the power control module.

[0044] Preferably, the analysis module further includes a flashback monitoring unit, which performs analysis based on the feedback parameters;

[0045] Analysis of UV sensor parameters, normal combustion range: During normal combustion, after multiple measurements and statistical analysis, it was found that the average photocurrent intensity received by the UV sensor was 50μA, with a fluctuation range of ±10μA; the flashback judgment threshold was set, and when the photocurrent intensity exceeded 1.5 times the average value during normal combustion and lasted for 10 seconds, it was determined to be a flashback phenomenon. This is because the flame propagates in the reverse direction during flashback, which will cause the UV sensor to receive stronger UV radiation, resulting in a significant increase in the photocurrent intensity.

[0046] Visible light sensor parameter analysis, brightness threshold, under normal flame conditions, the current change value corresponding to the flame brightness detected by the visible light sensor is about 20mA on average, and the normal fluctuation range is between ±5mA. When the detected current change value exceeds 30mA, which is 50% higher than the normal average value, and lasts for 12 seconds, it is determined to be a flashback phenomenon; color-related threshold, from a color perspective, a certain color characteristic value corresponding to the flame color during normal combustion, such as a value indicating the flame color bias calculated by a specific algorithm, assuming that the value range is between 0-1, 0 indicates the strongest blue tendency, 1 indicates the strongest red tendency, and is stable between 0.3-0.5. If the color characteristic value obtained by the visible light sensor analysis exceeds 0.7 and lasts for more than 6 seconds, accompanied by abnormal changes in brightness or other flame characteristics, it is determined to be a flashback phenomenon. This is because flashback may cause incomplete combustion, making the flame color more biased towards red, changing the normal color characteristic value;

[0047] Gas flow rate parameter analysis, normal flow rate range, taking the fuel gas supply pipeline as an example, during normal combustion, the gas flow rate is measured by the flow rate sensor and is stable between 8-10m / s, with a fluctuation range of ±1m / s; backfire judgment threshold setting: When the flow rate sensor detects that the gas flow rate suddenly drops below 5m / s, or the flow rate suddenly rises to more than 13m / s, which is more than 2m / s higher than the upper limit of the normal flow rate range of 11m / s, and this abnormal change in flow rate lasts for 15 seconds, it is determined to be a backfire phenomenon. This is because the reverse propagation of the flame during backfire will interfere with the normal flow of the gas, resulting in a significant change in the flow rate, either the flow rate decreases and the flame hinders the gas flow, or the flow rate increases, such as abnormal flow conditions such as backflow;

[0048] Gas pressure threshold, normal pressure range: Install a pressure sensor at a specific position inside the burner. During normal combustion, the measured gas pressure is stable between 100-120kPa, with a fluctuation range of ±10kPa. The flashback judgment threshold is set as follows: If the pressure sensor detects that the gas pressure suddenly rises to more than 140kPa (i.e., 20kPa higher than the upper limit of the normal pressure range of 120kPa), or the pressure suddenly drops to less than 80kPa (i.e., 20kPa lower than the lower limit of the normal pressure range of 100kPa), and this abnormal pressure change lasts for 10 seconds, it is determined that a flashback phenomenon has occurred. This is because flashback can cause a sudden change in gas pressure, and a local pressure increase may occur near the starting point of the flame's reverse propagation, while a pressure decrease may occur in other areas;

[0049] Temperature parameter analysis, including combustion zone temperature and pipeline temperature;

[0050] Temperature threshold of combustion area, normal temperature range: a temperature sensor is set near the flame of the plasma torch. During normal combustion, the temperature of this area is stable between 800-1000℃, with a fluctuation range of ±100℃ (i.e. 700℃-1100℃). The threshold for judging flashback is set: when the temperature sensor detects that the temperature of this area suddenly rises to more than 1200℃ (i.e. more than 200℃ higher than the upper limit of the normal temperature range of 1000℃), and this high temperature state lasts for 15 seconds, it is judged that flashback occurs. This is because the reverse propagation of the flame during flashback will change the temperature of the combustion area, which may cause a sudden increase in temperature. For example, the reverse propagation of the flame makes the high-temperature part that was originally far away from the combustion area closer to the sensor, or re-ignites the unburned fuel to generate additional heat.

[0051] Pipeline temperature threshold, normal temperature range: Install temperature sensors at key locations of the fuel supply pipeline. Under normal circumstances, the pipeline temperature is stable between 30-50°C, with a fluctuation range of ±5°C. The tempering judgment threshold is set: If the temperature sensor detects that the pipeline temperature suddenly rises to more than 70°C, which is more than 20°C higher than the upper limit of the normal temperature range of 50°C, and this high temperature state lasts for 12 seconds, it is judged as a tempering phenomenon. This is because tempering may spread along the pipeline, causing the pipeline temperature to rise, especially at the location where the flame contacts the pipeline wall, where the temperature rise will be more obvious;

[0052] Current parameter analysis: During normal ignition and combustion, the plasma current monitored by the current sensor is stable between 5-8A, with a fluctuation range of ±1A. When the current sensor detects that the current suddenly increases to more than 10A, which is more than 1A higher than the upper limit of the normal current range of 9A, and this abnormal current change lasts for 8 seconds, it is determined to be a flashback phenomenon. This is because the reverse propagation of the flame during flashback may change the conductive environment of the plasma, making it easier for the current to pass, resulting in an increase in the current;

[0053] Voltage parameters: For the voltage of plasma, it is normally stable between 300-400V, with a fluctuation range of ±50V (i.e. 250V-450V). If the voltage sensor detects that the voltage suddenly drops below 200V, that is, 50V lower than the lower limit of the normal voltage range of 250V, and this abnormal voltage change lasts for 10 seconds, it is determined to be a flashback phenomenon. This is because flashback may interfere with the electric field distribution of the plasma, causing the voltage to drop.

[0054] The workflow of the present invention is as follows:

[0055] S1, instruction receiving and preparation stage

[0056] Ignition execution module command reception: The command receiving unit of the ignition execution module has the ability to identify commands from multiple sources, and can receive remote start signals from the central control system, manual commands from the local control panel, and commands automatically triggered based on preset time programs. After receiving the command, the commands from different sources will be marked and classified so that they can be processed in a targeted manner according to the characteristics of the command.

[0057] Monitoring module data collection starts: At the same time, the monitoring module starts working and collects real-time data through various sensors, including voltage and current monitoring of electricity, flow and pressure parameter monitoring of gas, and the use of temperature signals and image recognition units to collect real-time information on the flame (such as monitoring the flame status through ultraviolet sensors and visible light sensors, and monitoring the flame temperature through temperature sensors, etc.).

[0058] S2, system status monitoring and analysis phase

[0059] Monitoring module data transmission: The monitoring module transmits various types of real-time data collected to the communication module. The communication module receives this information through the internal communication bus, creates a table to record historical information, and then feeds this information back to the analysis module.

[0060] Analysis module status judgment: After the analysis module receives device information and external information from the monitoring module and the power control module (the power control module will provide relevant data when it is running), its judgment unit will preset the thresholds of various flame parameters, gas parameters, current and voltage parameters, etc. When each parameter does not exceed the threshold, it is judged as normal; when it exceeds the threshold, it is judged as abnormal. For the voltage and current parameters of the power control module, if the parameter value is between the range threshold and the upper threshold, it is marked as an adjustable parameter abnormality. When the parameter value exceeds the upper threshold, a shutdown signal is sent to each module.

[0061] S3, power control and regulation stage

[0062] Power control module initialization: If the analysis module determines that the system state can be ignited, the power control module starts working. Among them, the dynamic voltage adjustment unit drives the high-voltage power supply to smoothly transition from the standby state (usually a lower voltage value, such as zero or a lower standby voltage) to the working state. This process is achieved through the timer and pulse width modulation (PWM) module in the digital signal processor (DSP) or microcontroller.

[0063] Voltage adjustment and monitoring: During the operation of the power control module, the output current and voltage feedback signals of the high-voltage power supply are monitored in real time, and these real-time data are obtained by communicating with the built-in feedback circuit of the high-voltage power supply. On the one hand, it is compared with the preset soft start curve, which is the trajectory of the voltage increase over time under ideal conditions, taking into account the characteristics of the high-voltage power supply and the system's requirements for smooth start. If the monitored voltage or current feedback signal deviates greatly from the soft start curve, such as the voltage rises too fast or too slowly, it is determined to be a soft start abnormality, and corresponding corrective measures are taken immediately; on the other hand, the real-time parameter monitoring unit uses the acquired real-time data to calculate the parameters such as the resistance and power of the plasma according to Ohm's law and the power calculation formula to determine the generation of plasma.

[0064] S4, ignition trigger and execution stage

[0065] Ignition condition confirmation: When the monitoring module confirms that the status of each device is normal, and the power control module increases the voltage to the value required for ignition and forms a stable plasma discharge, the system meets the ignition conditions.

[0066] Ignition operation execution: At this time, the ignition execution module triggers the ignition operation and formally starts the plasma long-term ignition process.

[0067] S5, Operation Monitoring and Feedback Stage

[0068] Continuous monitoring: After successful ignition, the system enters the operating state and each module continues to work. The monitoring module continuously collects various real-time data, such as flame status, gas parameters, power parameters, etc., to monitor the operation of the system.

[0069] Feedback and adjustment: The communication module transmits the system's operating status (such as equipment status, ignition progress, fault information, etc.) to external devices and the central control system in real time through Ethernet and wireless communication for remote monitoring and management. At the same time, if an abnormal situation is detected during the system operation (such as parameter abnormality determined by the analysis module), the relevant modules will make adjustments according to the preset mechanism, such as the power control module adjusting parameters such as voltage, and the ignition execution module taking corresponding actions according to the situation, etc., to ensure the continuous and stable operation of the system.

[0070] Example 2

[0071] This embodiment is different from Embodiment 1 and includes the following features:

[0072] The monitoring module also includes an environmental sensor and an equipment status monitoring unit.

[0073] Environmental sensors, such as new ambient temperature sensors, humidity sensors, and air pressure sensors, are added to the monitoring module to collect real-time data on the temperature, humidity, and air pressure of the surrounding environment. These data will be recorded along with other key parameters for subsequent analysis of the potential correlation between flashback and environmental factors. For example, environmental conditions vary greatly in different seasons or regions, and accurate recording of this information can help determine whether high humidity causes changes in gas conductivity, thereby affecting plasma formation and flashback.

[0074] Equipment status monitoring: Strengthen the monitoring of the status of key equipment components. For electrodes, wear monitoring sensors are installed to obtain real-time data on electrode wear; opening monitoring devices are installed at valves to record the change history of valve opening; for various sensors, calibration status monitoring functions are added to record the most recent calibration time and calibration results. Through these detailed monitoring methods, the equipment status can be more comprehensively understood, providing more detailed data for analyzing whether tempering is caused by changes in the status of equipment components.

[0075] High-frequency data collection during key periods greatly increases the data collection frequency of the monitoring module for periods when flashback is more likely to occur, such as the initial stage of the ignition process, the gas flow or pressure adjustment stage, and the period when the flame state is unstable. The data originally collected several times per second is increased to dozens of times per second or even higher during these key periods. For example, within the first 10 seconds after ignition, the ultraviolet and visible light intensity of the flame, the gas flow rate, pressure, and the voltage and current of the power supply are collected at a frequency of 50 times per second, so as to more accurately capture the continuous changes of various parameters in a short period of time, especially at the moment of flashback, to accurately record the rapid changes of various parameters.

[0076] The communication module also includes a data transmission unit and a data storage unit, as well as a data storage unit;

[0077] Data transmission unit, high-speed and stable transmission protocol: adopt a higher-speed and more stable internal communication bus protocol to ensure that the large amount of new data collected by the monitoring module and the data collected at high frequency can be quickly and accurately transmitted to other modules. For example, the original CAN bus protocol is upgraded to the more advanced Ethernet / IP protocol to improve the bandwidth and real-time performance of data transmission, avoid congestion and delays during data transmission, and ensure that each module can obtain the latest and most complete system operation information in a timely manner;

[0078] The data integrity assurance unit adds a data verification and error correction mechanism during the data transmission process. When receiving and sending data, the communication module verifies and calculates each packet of data, such as using the CRC (cyclic redundancy check) algorithm to ensure that no errors occur during data transmission. If data errors are found, error correction can be performed in a timely manner, such as requesting data to be resent, to ensure that the data transmitted to other modules such as the analysis module is accurate.

[0079] Data storage unit, equipped with a large-capacity storage device for the communication module, such as a solid-state drive (SSD), is used to store all data during the operation of the system, including daily operation data, tempering event data, and historical records of various parameters. This ensures that there is enough space to save a large amount of detailed data to meet the needs of long-term data recording and subsequent in-depth analysis. Detailed data recording format: formulate a more detailed data recording format. In addition to recording the values ​​of each parameter, it should also record the timestamp of data acquisition (accurate to milliseconds), data source (specifically which sensor or module), and related event descriptions (such as ignition operation start, gas flow adjustment, etc.). This detailed recording format facilitates subsequent classification, query and analysis of data, and can more clearly trace every detail of the system operation process.

[0080] The analysis module includes a big data analysis unit and a big data platform: a big data analysis platform is built inside the analysis module, and professional big data analysis software and tools are introduced, such as Apache Hadoop, Spark, etc. These platforms and tools can process massive amounts of data and have powerful data analysis capabilities, such as data mining, machine learning, etc., to provide technical support for in-depth analysis of tempering event data;

[0081] It also includes data preprocessing and integration: before importing the data from the communication module into the big data analysis platform, data preprocessing is performed first. This includes data cleaning, removing duplicate data, outliers, etc.; data standardization, unifying data of different formats and magnitudes into comparable standard forms; data integration, combining relevant data from different sensors and modules according to certain rules to form a complete data set. For example, the data of the flame monitoring sensor, the data of the gas supply system, and the data of the power control module are integrated for comprehensive analysis.

[0082] It also includes a unit for the application of in-depth analysis methods; Correlation analysis: Use the correlation analysis function of the big data analysis platform to perform correlation analysis on the integrated data set. Find out the correlation between different parameters, for example, determine whether there is a certain correlation between the flow rate and pressure of the gas and the voltage and current of the plasma, and how this correlation is related to the occurrence of the flashback phenomenon. Through correlation analysis, some rules hidden behind the data can be found, such as a specific gas composition, flow rate and pressure combination is more likely to cause flashback under specific power supply voltage and current conditions. Cluster analysis: Cluster analysis methods are used to cluster events with similar flashback characteristics. Flashback events are divided into different categories according to different parameter change trends, environmental conditions, equipment status and other factors. For example, flashback events that occur in a high temperature and high humidity environment are classified into one category, and flashback events caused by unstable gas supply are classified into another category. Through cluster analysis, we can have a deeper understanding of the characteristics of different types of flashback events, and provide a basis for formulating targeted prevention and treatment measures. Fault tree analysis: Use the fault tree analysis tool to construct a fault tree with the flashback phenomenon as the top event. Detailed analysis of various possible causes of flashback, such as abnormal gas supply (including unstable gas flow rate, abnormal gas pressure, etc.), power failure (such as voltage too high or too low, unstable current, etc.), inaccurate flame monitoring (such as UV sensor failure, visible light sensor failure, etc.) and poor equipment status (such as severe electrode wear, valve failure, etc.). Through the analysis of the fault tree, we can clearly see the importance of each cause in the flashback process and the logical relationship between them, which helps to accurately determine the root cause of the flashback from a system level.

[0083] The power control module also includes a data sharing and collaborative analysis unit and a parameter adjustment unit;

[0084] Data sharing and collaborative analysis unit, data is provided to the analysis module, the power control module should provide all relevant data generated during its operation, such as detailed parameter changes during voltage regulation, real-time status of current output, various indicators during soft start, etc., to the analysis module in a timely and complete manner. In this way, the analysis module can obtain more comprehensive system operation information when conducting in-depth analysis, so as to more accurately analyze the relationship between the flashback phenomenon and the power control module, and establish a collaborative analysis mechanism with the analysis module. When the analysis module is performing operations such as big data analysis or fault tree analysis, the power control module should actively cooperate and provide necessary technical support and expertise. For example, when analyzing the impact of the voltage regulation of the power control module on the flashback phenomenon, the technicians of the power control module can assist the analysis module in understanding the principles, methods and possible problems of voltage regulation, so as to more accurately find out the causes of the flashback.

[0085] Parameter adjustment unit based on analysis results, flexible parameter adjustment, according to the in-depth analysis results of the analysis module, the power control module formulates a flexible parameter adjustment strategy. If the analysis results show that excessive voltage is an important cause of flashback, then the power control module should be able to dynamically adjust the voltage output range and adjustment method according to different working conditions and environmental conditions. For example, in a high humidity environment, the upper limit of the voltage output is appropriately reduced to adapt to the impact of the environment on plasma formation and combustion, thereby effectively preventing the occurrence of flashback. Real-time feedback and optimization: After the parameter adjustment, the power control module should promptly feedback the adjusted parameter status and the operation status of the system to the analysis module. Based on these feedback information, the analysis module further evaluates the effectiveness of the adjustment strategy, and continues to analyze and adjust as needed to achieve the optimal operating state of the system and effectively prevent the occurrence of flashback.

[0086] The ignition execution module includes a data recording and feedback unit and an execution and adjustment unit;

[0087] Data recording and feedback unit, operation record provision, the ignition execution module shall provide all relevant operation records of itself during the ignition operation to the communication module for storage and recording. These operation records include the reception time of the ignition instruction, the ignition trigger time, the relevant parameter settings during the ignition operation (such as the contact method with the material to be ignited, the ignition energy transfer conditions, etc.). Through these operation records, the relationship between the ignition process and the flashback phenomenon can be more comprehensively understood, providing more basis for subsequent analysis, flashback feedback mechanism: establish a flashback feedback mechanism, when the ignition execution module detects the possible existence of flashback phenomenon (such as abnormal flame changes, the material to be ignited is not ignited normally, etc.), it shall immediately feedback the relevant information to the communication module, and the communication module shall pass it to the analysis module for further analysis and judgment. This ensures that once there is a sign of flashback during the ignition process, it can be discovered in time and included in the analysis scope.

[0088] Execution and adjustment unit, adjustment operation execution: According to the analysis results of the analysis module and the system adjustment strategy, the ignition execution module should actively cooperate in executing related adjustment operations. For example, if the analysis results show that the ignition method needs to be changed (such as adjusting the contact method between the material to be ignited and the plasma) to prevent the occurrence of flashback, the ignition execution module should make adjustments in a timely manner as required to ensure that the system can adapt to the new operating conditions and effectively prevent the occurrence of flashback. Emergency treatment measures: After the system flashes back and takes emergency measures such as shutdown, the ignition execution module should cooperate with other modules to carry out subsequent processing. For example, when restarting the system after shutdown, the ignition execution module should operate in accordance with the prescribed procedures and requirements to ensure the safety and smooth progress of the ignition process and avoid the occurrence of flashback again.

Claims

1. A plasma continuous ignition control system, characterized in that: It consists of a communication module, an ignition execution module, a power control module and a monitoring module; The communication module and the microcontroller perform data transmission through an internal communication bus to establish information and instruction interaction between various modules; The ignition execution module, when the monitoring module confirms that the status of each device is normal, the power control module starts to increase the voltage to the value required for ignition and forms a stable plasma discharge, the system triggers the ignition operation; The power control module system monitors the output current and voltage feedback signal of the high-voltage power supply in real time to ensure that the voltage rise process is smooth and conforms to the preset curve. If the voltage rise is abnormal, such as too fast or too slow, the microcontroller adjusts the soft start parameters or checks whether the high-voltage power supply has a fault; The monitoring module collects real-time data from various sensors, including voltage and current monitoring of electricity, flow and pressure parameter monitoring of gas, and real-time information of flames through temperature signals and image recognition units.

2. A plasma continuous ignition control system according to claim 1, characterized in that: It also includes an analysis module, which analyzes the equipment information and external information from the power control module and the monitoring module, and finally makes a status judgment on whether ignition can be performed.

3. A plasma continuous ignition control system according to claim 1, characterized in that: The communication module transmits the system's operating status, equipment status, ignition progress, and equipment failure information in real time to external devices and a central control system through Ethernet and wireless communications for remote monitoring and management; receives information from the monitoring module and the power control module through communications established through an internal communication bus, and establishes a table to record historical information; and then feeds the information back to the analysis module, which then feeds the information back to an external device or an ignition execution module after a preset ignition time.

4. A plasma continuous ignition control system according to claim 1, characterized in that: The power control module includes a dynamic voltage adjustment unit and a real-time parameter monitoring unit; The dynamic voltage adjustment unit drives the high voltage power supply to smoothly transition from a standby state, which is usually a lower voltage value, such as zero or a lower standby voltage, to a working state, which is achieved by a timer and a pulse width modulation (PWM) module in a digital signal processor (DSP) or a microcontroller; The real-time parameter monitoring unit continuously communicates with the built-in feedback circuit of the high-voltage power supply to obtain the output voltage and current data of the high-voltage power supply in real time, and uses these real-time data to calculate the resistance and power parameters of the plasma to determine the plasma condition.

5. A plasma continuous ignition control system according to claim 1, characterized in that: The ignition execution module also includes an instruction receiving unit, which has the ability to identify instructions from multiple sources, including remote start signals from the central control system, manual instructions from the local control panel, and instructions automatically triggered based on a preset time program, and mark and classify instructions from different sources so that targeted processing can be performed later based on the characteristics of the instructions.

6. A plasma continuous ignition control system according to claim 1, characterized in that: The monitoring module collects real-time information of the flame through the temperature signal and the image recognition unit, monitors the flame through the ultraviolet sensor and the visible light sensor, and also monitors the flame temperature through the temperature sensor.

7. A plasma continuous ignition control system according to claim 1, characterized in that: The monitoring module monitors the flow and pressure parameters of the gas, including gas flow rate monitoring, and installs pressure sensors at the gas supply position of the pipeline and the position inside the burner to monitor the pressure distribution of the gas.

8. A plasma continuous ignition control system according to claim 1, characterized in that: The analysis module also includes a judgment unit, which presets thresholds for various flame parameters, including range thresholds. When the threshold is not exceeded, the parameter is judged to be normal, and when the threshold is exceeded, the parameter is judged to be abnormal. An upper limit threshold is set, and a parameter value between the range threshold and the upper limit threshold is marked as an adjustable parameter abnormality. When the parameter value exceeds the upper limit threshold, a shutdown signal is sent to each module; and the adjustable parameter abnormality is limited to the voltage and current parameters of the power control module.

9. A plasma continuous ignition control system according to claim 1, characterized in that: The analysis module also includes a flashback monitoring unit, which performs analysis based on the parameters fed back by the monitoring module.

Images