An online detection system for pressure vessel deformation

Abstract

The present invention relates to the technical field of intelligent manufacturing equipment industry, specifically an online pressure vessel deformation detection system, the system comprising: a working condition data acquisition module, a boundary adjustment calculation module, a fluid-solid stress transfer module, a stress deformation update module, and a deformation risk assessment module. In the present invention, by real-time acquisition of wall temperature, local strain, external load, and shear stress gradient data, a multi-physical quantity correlation model is constructed to improve the integrity of deformation data, optimize stress state calibration, accurately adjust the stress boundary of the shell connection area, calculate the fluid-solid interface stress distribution, enhance stress change perception, optimize deformation adjustment strategy, improve prediction accuracy, locate deformation over-limit areas, enhance structural risk warning capabilities, realize data collaborative analysis, dynamically adjust monitoring parameters, improve deformation detection stability and adaptability, and ensure the safe operation of pressure vessels.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent manufacturing equipment industry, and in particular to an online deformation detection system for pressure vessels. Background Art

[0002] The technical field of the intelligent manufacturing equipment industry includes a technical system involving multiple aspects such as automation, intelligent perception, precision detection and efficient manufacturing. The core content of this technical field includes the use of sensors, data acquisition and analysis systems, automatic control systems and artificial intelligence algorithms to achieve real-time monitoring of the production and manufacturing process, data processing and intelligent decision-making. The overall technical field covers multiple links from raw material testing, processing process monitoring to final product quality testing, aiming to improve the accuracy, efficiency and stability of the manufacturing process. Among them, intelligent detection technology, as an important component of intelligent manufacturing equipment, covers multiple directions such as non-contact measurement, online monitoring, defect identification and deformation analysis, and is widely used in aerospace, energy equipment, automobile manufacturing and other fields to ensure the reliability of the manufacturing process and the consistency of product quality.

[0003] Among them, the pressure vessel deformation online detection system refers to a detection device and method for real-time deformation monitoring of containers subjected to high pressure. The subject of this patent mainly covers the collection and analysis of small deformation data during the operation of pressure vessels based on optical measurement, ultrasonic detection, laser interference or electromagnetic sensing. Its detection method usually includes obtaining the deformation of the container surface through a laser displacement sensor, analyzing the deformation trend with digital image processing technology, or measuring the stress distribution and structural integrity with an ultrasonic sensor. In addition, the system can use resistance strain gauges to monitor local stress concentration areas, and combine signal conditioning circuits and data calculation models to perform real-time evaluation of the pressure vessel deformation, thereby providing accurate data support for equipment operation.

[0004] Existing technologies rely on a single measurement method, and data acquisition is limited to local areas, making it difficult to reflect deformation trends under complex working conditions. Deformation analysis based on a single stress measurement lacks cross-validation of multiple physical quantities, resulting in low accuracy in identifying yield zone distribution and stress concentration areas. The fixed threshold judgment mode cannot adapt to changes in different materials and working conditions, and the monitoring results are difficult to adjust dynamically, affecting the ability to identify abnormal deformations. The stress-exceeding area is not captured in a timely manner, increasing the risk of sudden failure and affecting the stability of equipment operation. The deformation variable prediction accuracy is insufficient, and effective early warning data cannot be provided, reducing the reliability of pressure vessel deformation monitoring. Summary of the Invention

[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose an online detection system for pressure vessel deformation.

[0006] In order to achieve the above-mentioned object, the present invention adopts the following technical solution: an online detection system for pressure vessel deformation includes:

[0007] The working condition data acquisition module obtains the real-time wall temperature, local strain, external load, and shear stress gradient data of the pressure vessel, extracts the multi-point change rate and amplitude, calculates the correlation between multiple physical quantities, and obtains the change in working condition parameters;

[0008] The boundary adjustment calculation module collects the local strain rate, work hardening index, and yield strength dynamic change parameters of the pressure vessel wall material based on the change in the working condition parameters, calculates the distribution position of the yield zone, marks the stress state, calculates the yield criterion adjustment coefficient, updates the rigid-plastic boundary parameters of the shell connection area, determines the adjustment range, and obtains the matching boundary parameters;

[0009] The fluid-solid stress transfer module obtains shear stress gradient, pressure fluctuation, and separation area change data based on the matching boundary parameters, compares local stress, calculates the inner wall stress distribution trend, and obtains the fluid-solid interface stress distribution value;

[0010] The stress deformation update module calculates the deformation error of the weld joint based on the stress distribution value of the fluid-solid interface, adjusts the iteration step, collects current data, compares multi-point feedback data, and obtains a dynamic adjustment value of the stress deformation.

[0011] As a further solution of the present invention, the change in the operating parameters includes multi-point change rate, amplitude, and physical quantity correlation; the matching boundary parameters include yield zone distribution position, stress state, yield criterion adjustment coefficient, shell connection area rigid-plastic boundary parameters, and adjustment amplitude; the fluid-solid interface stress distribution value includes shear stress gradient, pressure fluctuation, separation area change data, local stress, and inner wall stress distribution trend; the stress deformation dynamic adjustment value includes welding joint deformation error, iteration step, current data, multi-point feedback data, and comparison results.

[0012] As a further solution of the present invention, the operating condition data acquisition module includes:

[0013] The wall temperature measurement submodule obtains the wall temperature data of the pressure vessel on site, detects the temperature change rate of multiple measuring points, calculates the temperature gradient between the multiple measuring points, filters the temperature data, eliminates the abnormal temperature measuring point data, calculates the temperature difference of the differentiated area based on the temperature change rate, and obtains the temperature change amplitude;

[0014] The strain and load extraction submodule extracts the local strain and external load data of the corresponding area based on the temperature change amplitude, calculates the strain rate and load increment, screens the fluctuation values ​​of the local strain and load, calculates the correlation between the local strain and load, and obtains the strain and load changes;

[0015] The stress gradient calculation submodule calls the strain and load changes, calculates the shear stress gradient, and analyzes the stress change trend using the formula:

[0016] ;

[0017] Calculate the shear stress change rate, calculate the stress change gradient, and obtain the change in working condition parameters;

[0018] in, represents the shear stress gradient, Representative The shear stress at each measuring point, represents the total number of shear stress measurement points, Representative External load at each measuring point, Representative The temperature change of each measuring point, Represents the total number of external load measurement points.

[0019] As a further solution of the present invention, the boundary adjustment calculation module includes:

[0020] The local strain calculation submodule collects the local strain rate of the pressure vessel wall material based on the change in the working condition parameters, calculates the relationship between the local strain rate and the work hardening index and the yield strength dynamic change parameters, and obtains the local strain calculation result;

[0021] The yield zone analysis submodule calls the local strain calculation results, calculates the yield zone distribution position, and marks the stress state using the formula:

[0022] ;

[0023] Calculate the yield criterion adjustment coefficient, and combine it with the rigid-plastic boundary parameters of the shell connection area to calculate the adjustment amplitude and obtain the yield zone adjustment parameter;

[0024] in, represents the yield criterion adjustment coefficient, Representative The local strain rate at Representative The cross-sectional area of ​​the material at Representative The yield strength at represents the initial yield strength, represents the total number of data points;

[0025] The rigid-plastic boundary adjustment submodule calls the yield zone adjustment parameters, updates the rigid-plastic boundary parameters of the shell connection area, calculates the matching degree between the rigid-plastic boundary parameters and the variation of the working condition parameters, and obtains the matching boundary parameters.

[0026] As a further solution of the present invention, the fluid-solid stress transfer module includes:

[0027] The shear stress calculation submodule obtains the velocity gradient data at the interface between the fluid and the solid based on the matching boundary parameters, compares the boundary layer thickness, calculates the wall shear stress, calls the shear stress distribution value, analyzes the shear stress gradient, and uses the formula:

[0028] ;

[0029] Calculate and obtain shear stress gradient;

[0030] in, represents the shear stress gradient, Representative The wall shear stress at represents the average wall shear stress, represents the total number of shear stress data points, Representative The viscosity of the fluid, Representative Fluid velocity at

[0031] The pressure fluctuation analysis submodule calls the shear stress gradient, compares the fluid pressure data, calculates the local pressure change rate, screens the pressure change peak, and obtains the pressure fluctuation value;

[0032] The inner wall stress distribution submodule calls the shear stress gradient and the pressure fluctuation value, compares the change trend of the separation area, calculates the local stress distribution, screens the inner wall stress extreme value, and obtains the fluid-solid interface stress distribution value.

[0033] As a further solution of the present invention, the stress deformation updating module includes:

[0034] The fluid-solid interface stress calculation submodule obtains the fluid-solid interface stress distribution value, calculates the fluid force and solid stress response, calculates the stress gradient in the fluid-solid interaction area based on multi-point feedback data, calculates the fluid-solid interface normal stress and shear stress, and screens the fluid-solid interaction stress characteristics by comparing the stress change rate at the junction of the flow area and the solid area to obtain the fluid-solid interaction stress characteristic value;

[0035] The weld joint deformation error assessment submodule calculates the stress distribution difference in the weld joint area based on the fluid-solid interaction stress characteristic value. Combined with the weld joint material properties and temperature influencing factors, the deformation amount and directional distribution of the weld joint are calculated using the formula:

[0036] ;

[0037] Calculate the deformation error value of the welding joint;

[0038] in, Represents the deformation error value of the welding joint, represents the elastic modulus of the material, represents the stress in the welding area, represents the thermal expansion coefficient of the material, represents the temperature change, represents the stress transfer coefficient, represents the stress gradient;

[0039] The stress and deformation dynamic adjustment submodule calls the welding joint deformation error value, adjusts the iteration step according to the error amplitude, dynamically corrects the deformation calculation accuracy, compares the error trends of multiple feedback points, collects the current stress state and calculates the deformation compensation amount to obtain the stress and deformation dynamic adjustment value.

[0040] As a further solution of the present invention, the deformation risk assessment module calculates the multi-region deformation deviation based on the stress deformation dynamic adjustment value, measures regional data, filters out regions exceeding the deviation threshold, calculates the distribution of the shell deformation exceeding limit area, and obtains the deformation risk assessment value;

[0041] The deformation risk assessment value includes multi-region deformation deviation, regional data, regions exceeding the deviation threshold, and the distribution of shell deformation exceeding limit areas.

[0042] As a further solution of the present invention, the deformation risk assessment module includes:

[0043] The deformation calculation submodule calculates the deformation of multiple regions based on the stress deformation dynamic adjustment value, and obtains the deformation deviation of multiple regions according to the calculation results, using the formula:

[0044] ;

[0045] Calculate the deviation value of multi-region deformation;

[0046] in, Representative area The deformation deviation value of Representative area No. The stress-strain variable measured at Representative area No. The theoretical deformation variable at The number of measurement points representing the area;

[0047] The over-limit area screening submodule calls the multi-region deformation variable deviation value, calculates the regional data, compares the multi-region deformation variable deviation value with the set deviation threshold, screens the area that exceeds the deviation threshold, and obtains the shell deformation over-limit area distribution;

[0048] The deformation risk assessment value calculation submodule calls the shell deformation over-limit area distribution, calculates the deformation risk assessment values ​​of multiple areas, and obtains the deformation risk assessment value by weighted summation based on the over-limit area distribution in the differentiated area and the corresponding deformation variable deviation value.

[0049] Compared with the prior art, the advantages and positive effects of the present invention are:

[0050] In the present invention, by collecting wall temperature, local strain, external load and shear stress gradient data in real time, a multi-physical quantity correlation model is constructed to achieve dynamic matching between different parameters and improve the integrity of deformation data. Combined with the strain rate, work hardening index and yield strength changes, the stress state calibration is optimized to make the stress boundary adjustment of the shell connection area more accurate. Based on the shear stress gradient and pressure fluctuation data, the stress distribution of the fluid-solid interface is calculated to improve the accurate perception of stress changes. By calculating the deformation error of the welding joint and comparing the multi-point feedback data, the deformation adjustment strategy is optimized to improve the prediction accuracy. Combined with the calculation of multi-region deformation deviation, the deformation exceeding limit area is accurately located to enhance the early warning capability of equipment structure risks. This solution realizes multi-level data collaborative analysis, dynamically adjusts monitoring parameters, improves the stability and adaptability of deformation detection, and provides accurate support for the safe operation of pressure vessels. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 is a system flow chart of the present invention;

[0052] Figure 2 This is a flow chart of the working condition data acquisition module of the present invention;

[0053] Figure 3 This is a flow chart of the boundary adjustment calculation module of the present invention;

[0054] Figure 4 This is a flow chart of the fluid-solid stress transfer module of the present invention;

[0055] Figure 5 This is a flow chart of the stress deformation update module of the present invention;

[0056] Figure 6 This is a flow chart of the deformation risk assessment module of the present invention. DETAILED DESCRIPTION

[0057] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0058] In the description of the present invention, it should be understood that the terms "length," "width," "up," "down," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," and the like, indicating positions or relationships, are based on the positions or relationships shown in the accompanying drawings and are intended only to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting the present invention. Furthermore, in the description of the present invention, "plurality" means two or more, unless otherwise expressly and specifically defined. Example 1

[0059] See also Figure 1 , a pressure vessel deformation online detection system includes:

[0060] The working condition data acquisition module obtains the real-time wall temperature, local strain, external load, and shear stress gradient data of the pressure vessel, extracts the multi-point change rate and amplitude, calculates the correlation between multiple physical quantities, and obtains the change in working condition parameters;

[0061] The boundary adjustment calculation module collects the local strain rate, work hardening index, and yield strength dynamic change parameters of the pressure vessel wall material based on the change in working condition parameters, calculates the distribution position of the yield zone, marks the stress state, calculates the yield criterion adjustment coefficient, updates the rigid-plastic boundary parameters of the shell connection area, determines the adjustment range, and obtains the matching boundary parameters;

[0062] The fluid-solid stress transfer module obtains shear stress gradient, pressure fluctuation, and separation area change data based on matching boundary parameters, compares local stress, calculates the inner wall stress distribution trend, and obtains the fluid-solid interface stress distribution value;

[0063] The stress and deformation update module calculates the deformation error of the weld joint based on the stress distribution value of the fluid-solid interface, adjusts the iteration step size, collects current data, compares multi-point feedback data, and obtains the dynamic adjustment value of stress and deformation;

[0064] The deformation risk assessment module calculates the multi-region deformation deviation based on the dynamic adjustment value of stress deformation, measures regional data, filters out areas exceeding the deviation threshold, calculates the distribution of shell deformation excess areas, and obtains the deformation risk assessment value.

[0065] The change in operating parameters includes multi-point change rate, amplitude, and physical quantity correlation. The matching boundary parameters include yield zone distribution position, stress state, yield criterion adjustment coefficient, rigid-plastic boundary parameters of the shell connection area, and adjustment amplitude. The fluid-solid interface stress distribution value includes shear stress gradient, pressure fluctuation, separation area change data, local stress, and inner wall stress distribution trend. The dynamic adjustment value of stress deformation includes welding joint deformation error, iteration step, current data, multi-point feedback data, and comparison results. The deformation risk assessment value includes multi-region deformation deviation, regional data, area exceeding the deviation threshold, and distribution of shell deformation overlimit area.

[0066] See also Figure 2 , the working condition data acquisition module includes:

[0067] The wall temperature measurement submodule obtains the wall temperature data of the pressure vessel on site, detects the temperature change rate of multiple measuring points, calculates the temperature gradient between the multiple measuring points, filters the temperature data, eliminates the abnormal temperature measuring point data, calculates the temperature difference of the differentiated area based on the temperature change rate, and obtains the temperature change amplitude;

[0068] The wall temperature measurement submodule is used to obtain the on-site wall temperature data of the pressure vessel, detect the temperature change rate of multiple measuring points, calculate the temperature gradient between multiple measuring points, filter the temperature data to eliminate abnormal measuring point data, and calculate the temperature difference of the differentiated area based on the temperature change rate to obtain the temperature change amplitude. Among them, the wall temperature data is obtained through temperature sensors at multiple measuring points. The initial temperature and continuous monitoring temperature data of each measuring point need to be recorded and the temperature change rate is calculated. The specific process includes: In time Temperature Record and calculate the temperature change rate at each time interval , such as for the measuring point The temperature changes from 350K to 355K within 10s, so the temperature change rate is K / s, after calculating the temperature change rate of all measuring points, filter out those exceeding the threshold Abnormal measurement points, such as setting thresholds K / s, then all the measurement point data exceeding the threshold value must be eliminated and will not enter the subsequent calculation. The temperature gradient, that is, the temperature difference between adjacent measurement points, is calculated for the filtered data. , such as measuring point and The temperatures are 355K and 360K respectively, then the temperature gradient is , and then calculate the temperature difference of the differentiated area, which is calculated by the maximum and minimum temperatures of all measuring points in the area. For example, if the maximum temperature of the measuring points in the area is 370K and the minimum is 345K, then the temperature difference of the area is , and finally get the temperature change amplitude For example, the amplitude calculated this time is 25K. This result shows that the temperature distribution in this area has large fluctuations, indicating that there is obvious heat transfer imbalance at different positions inside the pressure vessel. This result can be used as the basic data for subsequent strain and load extraction analysis, and further used to evaluate the impact of local thermal stress.

[0069] The strain and load extraction submodule extracts the local strain and external load data of the corresponding area based on the temperature change amplitude, calculates the strain rate and load increment, screens the fluctuation values ​​of local strain and load, calculates the correlation between local strain and load, and obtains the strain and load changes;

[0070] The strain and load extraction submodule extracts the local strain and external load data of the corresponding area according to the temperature change amplitude, calculates the strain rate and load increment, filters the fluctuation value of local strain and load, and calculates the correlation between the two, thereby obtaining the strain and load variation. Among them, the strain sensor collects data for the measuring points in the area. Suppose a measuring point is at time The strain value is , then calculate the strain rate , such as measuring point In 10s, the strain is Change to , then the strain rate is Similarly, monitor the external load data and set the external load In time The record value is N. N. N, then calculate the load increment ,like N, filter all strain rates and load increments and remove data that exceeds the set threshold, such as setting the strain rate threshold , load increment threshold N, then the data exceeding this range are eliminated, and then the correlation between local strain and load is calculated, that is, the Pearson correlation coefficient is used , if the calculation result is , indicating that the two are highly correlated. This result shows that the strain in this area is mainly affected by the external load and has an indirect relationship with the temperature change. This result can be used for subsequent stress gradient calculations to determine the loading characteristics of different areas.

[0071] The stress gradient calculation submodule calls the strain and load changes, calculates the shear stress gradient, and analyzes the stress change trend using the formula:

[0072] ;

[0073] Calculate the shear stress change rate, calculate the stress change gradient, and obtain the change in working condition parameters;

[0074] in, represents the shear stress gradient, Representative The shear stress at each measuring point, represents the total number of shear stress measurement points, Representative External load at each measuring point, Representative The temperature change of each measuring point, Represents the total number of external load measurement points.

[0075] The stress gradient calculation submodule calls the strain and load changes, calculates the shear stress gradient, and analyzes the stress change trend using the formula:

[0076] ;

[0077] in is the shear stress value, is the number of shear stress measurement points, is the external load, is the temperature change. If the shear stress value is [20, 25, 30, 40] MPa, calculate ;

[0078] Assumptions , then the average gradient of shear stress change is:

[0079] ;

[0080] If the load is [1000, 1200, 1350]N and the temperature change is [5, 10, 15]K, then calculate ;

[0081] Final shear stress gradient:

[0082] ;

[0083] The results show that the shear stress gradient is large, indicating that the load change in this area has a significant impact on the shear stress distribution, and there may be a large stress concentration phenomenon in the local structure. This result can be used to further analyze the fatigue characteristics of the structure and optimize the local force design to reduce structural risks.

[0084] See also Figure 3 , the boundary adjustment calculation module includes:

[0085] The local strain calculation submodule collects the local strain rate of the pressure vessel wall material based on the change in working condition parameters, calculates the relationship between the local strain rate and the dynamic change parameters of the work hardening index and yield strength, and obtains the local strain calculation results;

[0086] The local strain calculation submodule collects the local strain rate of the pressure vessel wall material based on the change in working condition parameters, calculates the relationship between the local strain rate and the work hardening index and the dynamic change parameters of the yield strength, and obtains the local strain calculation results. Among them, the change in working condition parameters is obtained through real-time monitoring data of temperature, load and pressure. Multiple measuring points are set, and the initial strain value is collected at each measuring point. and the strain values ​​at consecutive time points , calculate the local strain rate For example, set the measuring point The initial strain is 0.0015, and the strain change after 10 seconds is 0.002, so the strain rate s , also obtain the material work hardening index , which can be determined by fitting the material yield strength with the stress-strain curve data. For example, if the initial yield strength is MPa, ultimate yield strength MPa, then the work hardening index ,like , , then calculate , and then calculate the dynamic change parameters of yield strength , which is calculated based on the initial yield strength, current strain rate and work hardening index , substitute the above values MPa. This result shows that the yield strength of the material is dynamically adjusted with the change of strain rate, and its small change in value can directly affect the subsequent yield zone analysis and boundary adjustment calculation.

[0087] The yield zone analysis submodule calls the local strain calculation results, calculates the yield zone distribution position, and marks the stress state using the formula:

[0088] ;

[0089] Calculate the yield criterion adjustment coefficient, and combine it with the rigid-plastic boundary parameters of the shell connection area to calculate the adjustment amplitude and obtain the yield zone adjustment parameter;

[0090] in, represents the yield criterion adjustment coefficient, Representative The local strain rate at Representative The cross-sectional area of ​​the material at Representative The yield strength at represents the initial yield strength, represents the total number of data points;

[0091] The yield zone analysis submodule calls the local strain calculation results, calculates the yield zone distribution position, marks the stress state, calculates the yield criterion adjustment coefficient, and combines the rigid-plastic boundary parameters of the shell connection area to calculate the adjustment amplitude to obtain the yield zone adjustment parameters. Among them, the yield zone distribution position is based on the strain rate of each measuring point. and the corresponding cross-sectional area , the yield criterion adjustment coefficient is calculated using the weighted mean:

[0092] ;

[0093] Among them, set the number of measurement points , strain rate data , cross-sectional area mm2, then calculate:

[0094] ;

[0095] ;

[0096] ;

[0097] Similarly, calculate the yield strength change part, assuming the yield strength data MPa, initial yield strength MPa, then calculate:

[0098] ;

[0099] ;

[0100] ;

[0101] ;

[0102] The results show that the adjustment coefficient of the yield zone criterion is large, indicating that the yield zone is distributed in the region of higher strain rate. This result is used in the subsequent rigid-plastic boundary adjustment calculation.

[0103] Table 1: Calculation data of local strain, cross-sectional area and yield strength

[0104]

[0105] Table 1 lists the local strain rate, cross-sectional area, yield strength and their change data of the measuring points.

[0106] The rigid-plastic boundary adjustment submodule calls the yield zone adjustment parameters, updates the rigid-plastic boundary parameters of the shell connection area, calculates the matching degree with the change of the working condition parameters, and obtains the matching boundary parameters.

[0107] The rigid-plastic boundary adjustment submodule calls the yield zone adjustment parameters, updates the rigid-plastic boundary parameters of the shell connection area, calculates the matching degree with the change in the working condition parameters, and obtains the matching boundary parameters. The matching degree calculation is based on the yield zone adjustment parameters. Compare with the rigid-plastic characteristics of the boundary area and calculate its relative deviation , assuming that the base boundary parameters of the shell connection area , then calculate:

[0108] ;

[0109] If the matching threshold is set to , then the matching degree is determined to be insufficient and the boundary parameters need to be adjusted. The adjustment range is calculated as:

[0110] ;

[0111] The adjusted matching boundary parameters are:

[0112] ;

[0113] The results show that the rigid-plastic boundary parameter needs to be adjusted by 0.50006 to meet the change in yield zone distribution. This result can be used for subsequent structural optimization calculations.

[0114] See also Figure 4 , the fluid-solid stress transfer module includes:

[0115] The shear stress calculation submodule obtains the velocity gradient data at the interface between the fluid and the solid based on the matching boundary parameters, compares the boundary layer thickness, calculates the wall shear stress, calls the shear stress distribution value, and analyzes the shear stress gradient using the formula:

[0116] ;

[0117] Calculate and obtain shear stress gradient;

[0118] in, represents the shear stress gradient, Representative The wall shear stress at represents the average wall shear stress, represents the total number of shear stress data points, Representative The viscosity of the fluid, Representative Fluid velocity at

[0119] The shear stress calculation submodule obtains the velocity gradient data at the interface between the fluid and the solid based on the matching boundary parameters, compares the boundary layer thickness, calculates the wall shear stress, calls the shear stress distribution value, and analyzes the shear stress gradient. Obtained through the above calculation, this value is used to calculate the wall shear stress The calculation of wall shear stress requires the velocity gradient at the interface between the fluid and the wall. , fluid dynamic viscosity , the wall shear stress is calculated as:

[0120] ;

[0121] Where, the dynamic viscosity of the fluid is Pa·s, fluid velocity gradient s , then calculate:

[0122] ;

[0123] Compare the wall shear stress at different measuring points and calculate the average shear stress , set the shear stress data of the measuring point Pa, then calculate:

[0124] ;

[0125] The shear stress gradient is calculated using the formula:

[0126] ;

[0127] Calculate the molecular part:

[0128] ;

[0129] ;

[0130] Calculate the denominator, assuming the fluid velocity m / s, corresponding to dynamic viscosity Pa·s, then:

[0131] ;

[0132] After calculation:

[0133] ;

[0134] ;

[0135] Finally the shear stress gradient is calculated:

[0136] ;

[0137] The results show that the shear stress gradient at the current measuring point is small, indicating that the wall shear stress distribution is relatively uniform. This result can be used for subsequent pressure fluctuation analysis.

[0138] The pressure fluctuation analysis submodule calls the shear stress gradient, compares the fluid pressure data, calculates the local pressure change rate, filters the pressure change peak, and obtains the pressure fluctuation value;

[0139] The pressure fluctuation analysis submodule calls the shear stress gradient, compares the fluid pressure data, calculates the local pressure change rate, filters the pressure change peak, and obtains the pressure fluctuation value. The local pressure change rate is calculated by the pressure data of the measuring point. Assume that the pressure data of the measuring point MPa, calculate the pressure change rate:

[0140] ;

[0141] ;

[0142] Set the pressure change rate threshold to 0.05 MPa, filter out data greater than this value as the pressure change peak, and calculate the pressure fluctuation value:

[0143] ;

[0144] The results show that the pressure fluctuation is small, indicating that the pressure change in the wall area is stable. This result can be used for subsequent calculation of the inner wall stress distribution.

[0145] The inner wall stress distribution submodule calls the shear stress gradient and pressure fluctuation values, compares the change trend of the separation area, calculates the local stress distribution, screens the inner wall stress extreme value, and obtains the fluid-solid interface stress distribution value.

[0146] The inner wall stress distribution submodule calls the shear stress gradient and pressure fluctuation value, compares the change trend of the separation area, calculates the local stress distribution, screens the inner wall stress extreme value, and obtains the fluid-solid interface stress distribution value. Among them, the local stress distribution calculation uses the wall shear stress gradient and pressure fluctuation values , calculate the regional stress distribution:

[0147] ;

[0148] ;

[0149] Screen the extreme values ​​of inner wall stress and set regional measuring point stress data MPa, the extreme value is:

[0150] ;

[0151] ;

[0152] Finally, the stress distribution value of the fluid-solid interface is obtained:

[0153] ;

[0154] The results show that the stress distribution at the fluid-solid interface is relatively uniform, and there is no obvious stress concentration phenomenon. The results can be used for subsequent structural stability assessment.

[0155] Table 2: Shear stress, fluid velocity and pressure data

[0156]

[0157] Table 2 lists the wall shear stress, fluid velocity, fluid viscosity, and fluid pressure data for subsequent calculations.

[0158] See also Figure 5 , the stress deformation update module includes:

[0159] The fluid-solid interface stress calculation submodule obtains the fluid-solid interface stress distribution value, calculates the fluid force and solid stress response, calculates the stress gradient in the fluid-solid interaction area based on multi-point feedback data, calculates the fluid-solid interface normal stress and shear stress, and screens the fluid-solid interaction stress characteristics by comparing the stress change rate at the junction of the flow area and the solid area to obtain the fluid-solid interaction stress characteristic value;

[0160] The fluid-solid interface stress calculation submodule obtains the fluid-solid interface stress distribution value, calculates the fluid force and solid stress response, calculates the stress gradient in the fluid-solid interaction area based on multi-point feedback data, calculates the fluid-solid interface normal stress and shear stress, and screens the fluid-solid interaction stress characteristics by comparing the stress change rate at the junction of the flow area and the solid area, and obtains the fluid-solid interaction stress characteristic value. Among them, the fluid-solid interface stress distribution value is obtained through multiple measuring points, and the stress data Shear stress through the wall and normal stress Calculated, for example, if the shear stress is [0.6, 0.8, 0.75, 0.85, 0.7] Pa, normal stress is [2.5, 2.6, 2.55, 2.7, 2.65] MPa, then calculate the mean stress:

[0161] ;

[0162] Calculate the stress gradient in the fluid-solid interaction region and set the coordinates of the measuring points in the region is [0.1, 0.2, 0.3, 0.4, 0.5] m, and the stress gradient is calculated as:

[0163] ;

[0164] ;

[0165] Calculation of fluid-solid interface normal stress and shear stress ,set up:

[0166] ;

[0167] ;

[0168] The fluid-solid interaction stress characteristics are screened, and the stress change rate threshold is set to 0.4 MPa / m to determine whether it exceeds this range. The current stress gradient is 0.5 MPa / m, which meets the screening conditions. The fluid-solid interaction stress characteristic value is 0.5 MPa / m. This result shows that the fluid-solid interaction stress characteristics in this area vary greatly, indicating that the fluid force has a significant impact on the solid stress. This result is used for the subsequent calculation of the deformation error of the weld joint.

[0169] The weld joint deformation error assessment submodule calculates the stress distribution difference in the weld joint area based on the fluid-solid interaction stress characteristic value. Combined with the weld joint material properties and temperature influencing factors, the deformation amount and directional distribution of the weld joint are calculated using the formula:

[0170] ;

[0171] Calculate the deformation error value of the welding joint;

[0172] in, Represents the deformation error value of the welding joint, represents the elastic modulus of the material, represents the stress in the welding area, represents the thermal expansion coefficient of the material, represents the temperature change, represents the stress transfer coefficient, represents the stress gradient;

[0173] The welding joint deformation error evaluation submodule calculates the stress distribution difference of the welding joint area based on the fluid-solid interaction stress characteristic value, and calculates the deformation variable and directional distribution of the welding joint in combination with the material properties and temperature influencing factors of the welding joint, and calculates the deformation error value of the welding joint. Among them, the stress distribution difference in the welding area is determined by the elastic modulus of the material. and weld area stress Calculate and set the elastic modulus of the measuring point GPa, stress in welding area MPa, calculation:

[0174] ;

[0175]

[0176] Assume the thermal expansion coefficient of the material 1 / K, temperature change K, calculation:

[0177] ;

[0178] ;

[0179] Calculate the stress gradient transfer coefficient ,set up , stress gradient MPa / m, calculation:

[0180] ;

[0181] ;

[0182] Finally calculate the deformation error of the welding joint:

[0183] ;

[0184] The results show that the deformation error of the welded joint is large, indicating that the stress change has a significant impact on the deformation of the welded joint. This result is used for subsequent dynamic adjustment calculation of stress and deformation.

[0185] Table 3: Parameters for stress calculation of welded joints

[0186]

[0187] Table 3 lists the elastic modulus, stress in the welding area, thermal expansion coefficient, temperature change, stress gradient, and stress transfer coefficient of the weld joint, which are used for subsequent deformation error calculation.

[0188] The stress and deformation dynamic adjustment submodule calls the welding joint deformation error value, adjusts the iteration step according to the error amplitude, dynamically corrects the deformation calculation accuracy, compares the error trends of multiple feedback points, collects the current stress state and calculates the deformation compensation amount to obtain the stress and deformation dynamic adjustment value.

[0189] The stress deformation dynamic adjustment submodule calls the welding joint deformation error value, adjusts the iteration step according to the error amplitude, dynamically corrects the deformation calculation accuracy, compares the error trends of multiple feedback points, collects the current stress state and calculates the deformation compensation amount to obtain the stress deformation dynamic adjustment value, among which the iteration step adjustment is based on the error amplitude. If the error exceeds 100,000, set the iteration step to 0.5, otherwise set it to 0.2. The error this time is 163242.4, set the step to 0.5, and calculate the corrected deformation:

[0190] ;

[0191] Compare the error trends of multiple feedback points, set the early error to [150000, 155000, 160000], and calculate the trend mean:

[0192] ;

[0193] The current error 163242.4 exceeds the trend mean. Calculate the deformation compensation amount:

[0194] ;

[0195] Finally, the dynamic adjustment value of stress and deformation is obtained:

[0196] ;

[0197] The results show that the stress-strain variables need to be adjusted by 73378.8 to match the error correction target. This result can be used to optimize structural stress analysis.

[0198] See also Figure 6 , deformation risk assessment module includes:

[0199] The deformation calculation submodule calculates the deformation of multiple regions based on the dynamic adjustment value of stress deformation, and obtains the deformation deviation of multiple regions according to the calculation results using the formula:

[0200] ;

[0201] Calculate the deviation value of multi-region deformation;

[0202] in, Representative area The deformation deviation value of Representative area No. The stress-strain variable measured at Representative area No. The theoretical deformation variable at The number of measurement points representing the area;

[0203] The deformation calculation submodule calculates the deformation of multiple regions based on the dynamic adjustment value of stress deformation, and obtains the deformation deviation of multiple regions according to the calculation results. The value obtained through the above calculation is used to calculate the deformation of each region. The stress deformation of the measuring point is set to The theoretical deformation is obtained by calculating the structural stress response. Based on the material elastic modulus and stress gradient calculation, the deformation deviation is calculated using the formula:

[0204] ;

[0205] Set the number of regional measurement points , measuring deformation mm, theoretical deformation mm, then calculate:

[0206] ;

[0207] ;

[0208] ;

[0209] The results show that the deviation of regional deformation variables is small, indicating that the measured deformation variables are relatively close to the theoretical deformation variables. This result is used for subsequent over-limit area screening calculations.

[0210] The over-limit area screening submodule calls the multi-region deformation variable deviation value, calculates the regional data, compares the multi-region deformation variable deviation value with the set deviation threshold, screens the area that exceeds the deviation threshold, and obtains the shell deformation over-limit area distribution;

[0211] The over-limit area screening submodule calls the multi-region deformation variable deviation value, calculates the regional data, compares the multi-region deformation variable deviation value with the set deviation threshold, screens the area exceeding the deviation threshold, and obtains the shell deformation over-limit area distribution, wherein the set deviation threshold 0.01mm, calculate the over-limit area, set the measurement point deformation deviation ,judge:

[0212] ;

[0213] Filter out the over-limit areas:

[0214] ;

[0215] Mark the corresponding area and set the measurement point area number , corresponding to the over-limit area:

[0216] ;

[0217] The results show that the deformation deviations in regions B and C exceed the threshold, indicating that these regions have over-limit deformations. The results are used for subsequent deformation risk assessment value calculations.

[0218] Table 4: Multi-region deformation deviation data table

[0219]

[0220] Table 4 lists the measuring point numbers, measured deformation variables, theoretical deformation variables, calculated deformation variable deviations, and the judgment results of whether they exceed the limit.

[0221] The deformation risk assessment value calculation submodule calls the shell deformation over-limit area distribution, calculates the deformation risk assessment values ​​of multiple areas, and obtains the deformation risk assessment value by weighted summation based on the over-limit area distribution in the differentiated area and the corresponding deformation variable deviation value.

[0222] The deformation risk assessment value calculation submodule calls the shell deformation over-limit area distribution to calculate the deformation risk assessment values ​​of multiple areas. It performs weighted summation based on the over-limit area distribution within the differentiated area and the corresponding deformation deviation value to obtain the deformation risk assessment value. The deformation risk assessment value calculation formula is:

[0223] ;

[0224] Set the number of over-limit areas , corresponding to the deformation deviation , set the weight ,calculate:

[0225] ;

[0226] ;

[0227] The results show that the deformation risk assessment value is small, indicating that the overall structural deformation risk is within a controllable range. The results can be used for subsequent deformation correction or structural optimization.

[0228] The above are merely preferred embodiments of the present invention and do not limit the present invention in any other form. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall still fall within the scope of protection of the technical solution of the present invention.

Claims

1. An online pressure vessel deformation detection system, characterized in that: The system comprises: The working condition data acquisition module obtains the real-time wall temperature, local strain, external load, and shear stress gradient data of the pressure vessel, extracts the multi-point change rate and amplitude, calculates the correlation between multiple physical quantities, and obtains the change in working condition parameters; The boundary adjustment calculation module collects the local strain rate, work hardening index, and yield strength dynamic change parameters of the pressure vessel wall material based on the change in the working condition parameters, calculates the distribution position of the yield zone, marks the stress state, calculates the yield criterion adjustment coefficient, updates the rigid-plastic boundary parameters of the shell connection area, determines the adjustment range, and obtains the matching boundary parameters; The fluid-solid stress transfer module obtains shear stress gradient, pressure fluctuation, and separation area change data based on the matching boundary parameters, compares local stress, calculates the inner wall stress distribution trend, and obtains the fluid-solid interface stress distribution value; The stress and deformation update module calculates the deformation error of the weld joint based on the stress distribution value of the fluid-solid interface, adjusts the iteration step, collects current data, compares multi-point feedback data, and obtains a dynamic adjustment value of stress and deformation; The operating condition parameter changes include multi-point change rate, amplitude, and physical quantity correlation; the matching boundary parameters include yield zone distribution position, stress state, yield criterion adjustment coefficient, shell connection area rigid-plastic boundary parameters, and adjustment amplitude; the fluid-solid interface stress distribution value includes shear stress gradient, pressure fluctuation, separation area change data, local stress, and inner wall stress distribution trend; the stress deformation dynamic adjustment value includes weld joint deformation error, iteration step, current data, multi-point feedback data, and comparison results; The working condition data acquisition module includes: The wall temperature measurement submodule obtains the wall temperature data of the pressure vessel on site, detects the temperature change rate of multiple measuring points, calculates the temperature gradient between the multiple measuring points, filters the temperature data, eliminates the abnormal temperature measuring point data, calculates the temperature difference of the differentiated area based on the temperature change rate, and obtains the temperature change amplitude; The strain and load extraction submodule extracts the local strain and external load data of the corresponding area based on the temperature change amplitude, calculates the strain rate and load increment, screens the fluctuation values ​​of the local strain and load, calculates the correlation between the local strain and load, and obtains the strain and load changes; The stress gradient calculation submodule calls the strain and load changes, calculates the shear stress gradient, and analyzes the stress change trend using the formula: ； Calculate the shear stress change rate, calculate the stress change gradient, and obtain the change in working condition parameters; in, represents the shear stress gradient, Representative The shear stress at each measuring point, Represents the total number of shear stress measurement points, External load at each measuring point, represents the temperature change of the nth measuring point, Represents the total number of external load measurement points; The boundary adjustment calculation module includes: The local strain calculation submodule collects the local strain rate of the pressure vessel wall material based on the change in the working condition parameters, calculates the relationship between the local strain rate and the work hardening index and the yield strength dynamic change parameters, and obtains the local strain calculation result; The yield zone analysis submodule calls the local strain calculation results, calculates the yield zone distribution position, and marks the stress state using the formula: ； Calculate the yield criterion adjustment coefficient, and combine it with the rigid-plastic boundary parameters of the shell connection area to calculate the adjustment amplitude and obtain the yield zone adjustment parameter; in, represents the yield criterion adjustment coefficient, Representative The local strain rate at Representative The cross-sectional area of ​​the material at Representative The yield strength at represents the initial yield strength, represents the total number of data points; The rigid-plastic boundary adjustment submodule calls the yield zone adjustment parameters, updates the rigid-plastic boundary parameters of the shell connection area, calculates the matching degree between the rigid-plastic boundary parameters and the variation of the working condition parameters, and obtains the matching boundary parameters.

2. The pressure vessel deformation online detection system according to claim 1, characterized in that: The fluid-solid stress transfer module includes: The shear stress calculation submodule obtains the velocity gradient data at the interface between the fluid and the solid based on the matching boundary parameters, compares the boundary layer thickness, calculates the wall shear stress, calls the shear stress distribution value, analyzes the shear stress gradient, and uses the formula: ； Calculate and obtain shear stress gradient; in, represents the shear stress gradient, Representative The wall shear stress at represents the average wall shear stress, represents the total number of shear stress data points, Representative The viscosity of the fluid, Representative Fluid velocity at The pressure fluctuation analysis submodule calls the shear stress gradient, compares the fluid pressure data, calculates the local pressure change rate, screens the pressure change peak, and obtains the pressure fluctuation value; The inner wall stress distribution submodule calls the shear stress gradient and the pressure fluctuation value, compares the change trend of the separation area, calculates the local stress distribution, screens the inner wall stress extreme value, and obtains the fluid-solid interface stress distribution value.

3. The pressure vessel deformation online detection system according to claim 2, characterized in that: The stress deformation updating module includes: The fluid-solid interface stress calculation submodule obtains the fluid-solid interface stress distribution value, calculates the fluid force and solid stress response, calculates the stress gradient in the fluid-solid interaction area based on multi-point feedback data, calculates the fluid-solid interface normal stress and shear stress, and screens the fluid-solid interaction stress characteristics by comparing the stress change rate at the junction of the flow area and the solid area to obtain the fluid-solid interaction stress characteristic value; The weld joint deformation error assessment submodule calculates the stress distribution difference in the weld joint area based on the fluid-solid interaction stress characteristic value. Combined with the weld joint material properties and temperature influencing factors, the deformation amount and directional distribution of the weld joint are calculated using the formula: ； Calculate the deformation error value of the welding joint; in, Represents the deformation error value of the welding joint, represents the elastic modulus of the material, represents the stress in the welding area, represents the thermal expansion coefficient of the material, represents the temperature change, represents the stress transfer coefficient, represents the stress gradient; The stress and deformation dynamic adjustment submodule calls the welding joint deformation error value, adjusts the iteration step according to the error amplitude, dynamically corrects the deformation calculation accuracy, compares the error trends of multiple feedback points, collects the current stress state and calculates the deformation compensation amount to obtain the stress and deformation dynamic adjustment value.

4. The pressure vessel deformation online detection system according to claim 3, characterized in that: The system further comprises: The deformation risk assessment module calculates the multi-region deformation deviation based on the stress deformation dynamic adjustment value, measures regional data, filters out regions exceeding the deviation threshold, calculates the distribution of the shell deformation exceeding limit area, and obtains the deformation risk assessment value; The deformation risk assessment value includes multi-region deformation deviation, regional data, regions exceeding the deviation threshold, and the distribution of shell deformation exceeding limit areas.

5. The pressure vessel deformation online detection system according to claim 4, characterized in that: The deformation risk assessment module includes: The deformation calculation submodule calculates the deformation of multiple regions based on the stress deformation dynamic adjustment value, and obtains the deformation deviation of multiple regions according to the calculation results, using the formula: ； Calculate the deviation value of multi-region deformation; in, Representative area The deformation deviation value of Representative area No. The stress-strain variable measured at Representative area No. The theoretical deformation variable at The number of measurement points representing the area; The over-limit area screening submodule calls the multi-region deformation variable deviation value, calculates the regional data, compares the multi-region deformation variable deviation value with the set deviation threshold, screens the area that exceeds the deviation threshold, and obtains the shell deformation over-limit area distribution; The deformation risk assessment value calculation submodule calls the shell deformation over-limit area distribution, calculates the deformation risk assessment values ​​of multiple areas, and obtains the deformation risk assessment value by weighted summation based on the over-limit area distribution in the differentiated area and the corresponding deformation variable deviation value.

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