Corrosion early warning system and working method thereof

Abstract

The invention relates to a corrosion early warning system and a working method thereof, and the system comprises a signal collection module which is used for collecting the environment temperature and humidity, oxygen concentration and corrosion current of a to-be-detected product; the communication module is connected with the signal acquisition module and is in communication connection with a far-end server side; and the server side is used for receiving the data fed back by the signal acquisition module, carrying out comprehensive judgment, determining whether the environment of the to-be-detected product has a corrosion risk or not, and giving an alarm. According to the invention, corrosion detection can be comprehensively realized, the corrosion detection sensitivity can be improved, management personnel can conveniently carry out corresponding treatment, the anti-rust protection performance is improved, and the corrosion risk is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of corrosion monitoring, and in particular to a corrosion early warning system and a working method thereof. Background Art

[0002] Rust refers to the chemical or electrochemical reaction of metal exposed to the atmosphere with oxygen, moisture and other impurities, causing discoloration or corrosion, and generating corrosion products that can be observed by the naked eye, such as metal oxides, hydroxides, etc. The corrosion product is rust, commonly known as rust or rust. For some high-value equipment, products, and even weapons and equipment, once rust is formed, the economic and safety losses it brings are irreparable. For example, large equipment and military equipment such as precision instruments, precision machine tools, radio equipment, tanks, artillery, ammunition, and aviation spare parts are characterized by high technical content, high value, and most of the parts are metal products. If they are not properly kept during transportation and storage, rust will inevitably occur, affecting the performance and accuracy. Therefore, in order to avoid rusting of equipment and equipment during transportation and storage, packaging technologies such as gas phase anti-rust sealing method, whole package envelope packaging method, and vacuum packaging method are usually used to package them during transportation and storage. However, even so, the above packaging may still fail, and the failure of packaging is hidden. Sometimes, equipment and equipment will rust due to the failure of packaging not being discovered in time. Therefore, it is particularly necessary to detect the maintenance of the anti-rust function inside the packaging. Although there are anti-rust monitoring devices in existing equipment, they basically stay in the detection of temperature and humidity, oxygen content, etc., and the monitoring effect is poor and lagging.

[0003] Therefore, how to adjust and achieve more accurate corrosion detection is the technical problem that this application solves. Summary of the invention

[0004] A main purpose of the present invention is to overcome at least one of the above-mentioned defects, and to provide a corrosion early warning system and a working method thereof, which have high corrosion detection sensitivity and fast response, and can better protect the target equipment or products.

[0005] To achieve the above object, the present invention provides a corrosion early warning system, which comprises: Signal acquisition module, used to collect the ambient temperature and humidity, oxygen concentration and corrosion current of the product to be tested; A communication module, connected to the signal acquisition module and communicating with a remote server; and The server receives the data fed back by the signal acquisition module and makes a comprehensive judgment to determine whether there is a corrosion risk in the environment of the product to be tested, and issues an alarm.

[0006] For the above technical solution, the applicant has further optimization measures.

[0007] Optionally, the signal acquisition module includes a temperature and humidity sensor and an oxygen concentration sensor, which are used to collect the ambient temperature, humidity and oxygen concentration of the product to be tested, and send the collected data to the server via the communication module.

[0008] Optionally, the signal acquisition module includes a diaphragm corrosion detector, wherein: The diaphragm corrosion detector comprises a substrate and a metal film layer, wherein the metal film layer is formed on at least one side of the substrate, and the metal film layer is composed of a plurality of metal films arranged in a regular shape, wherein the metal films are arranged regularly and evenly, and the metal films are parallel to each other to form a ring-shaped pattern, and the spacing between the metal films is 0.05-0.15 mm; The metal film corrodes in an oxygen-containing and humid environment, and generates the corrosion current after power is turned on. The collected corrosion current is sent to the server end via the communication module.

[0009] Optionally, each metal film has a width of 0.1-0.2 mm and a thickness of 1-2 μm.

[0010] Optionally, the metal film layer is made of high-purity iron of 2N or above.

[0011] Optionally, the diaphragm corrosion detector further includes a guide electrode, which is formed on the same side as the metal film layer, and both ends of the metal film layer are respectively connected to a guide electrode, and the guide electrode is used to connect to an external detection and processing circuit.

[0012] Optionally, the minimum monitoring impedance sensitivity of the diaphragm corrosion detector is on the order of uΩ.

[0013] The present application also provides a working method of the corrosion early warning system as described above, which comprises the following working steps: The signal acquisition module collects the ambient temperature, humidity and oxygen concentration of the product to be tested at regular intervals, and generates corrosion current through a membrane corrosion detector that can oxidize and corrode; The temperature and humidity signal, oxygen concentration signal and corrosion current signal obtained by the signal acquisition module are sent to the server via the communication module; The server side stores the obtained temperature and humidity signals, oxygen concentration signals and corrosion current signals, and compares the temperature and humidity signals, oxygen concentration signals and corrosion current signals with set thresholds, and issues an alarm if any one of the temperature and humidity signals, oxygen concentration signals and corrosion current signals is greater than the corresponding threshold.

[0014] Similarly, for the above technical solution, the applicant has further optimization measures.

[0015] Optionally, the signal acquisition module works based on a sleep-and-wake-up mode, and wakes up every 30 to 60 minutes, and works for 1 to 2 minutes after waking up to collect the temperature and humidity signals, oxygen concentration signals, and corrosion current signals, and interacts with the server to adjust the sleep time or working time.

[0016] Optionally, the server records the initial magnitude of the corrosion current signal and monitors its value change, and issues a first-level alarm when the value change is greater than a preset threshold; The server monitors the temperature and humidity signals and the oxygen concentration signals, and issues a second-level alarm if one of the two is greater than a preset threshold, and determines whether to issue a first-level alarm based on the magnitude of the excess threshold; The level of the first level alarm is higher than that of the second level alarm.

[0017] Compared with the prior art, the corrosion early warning system and working method of the present invention patent application have the following advantages and beneficial effects: The corrosion warning system of the present application combines temperature and humidity, oxygen concentration, and corrosion current detection by a new structure corrosion detector to comprehensively realize corrosion detection and improve the sensitivity of corrosion detection. The diaphragm corrosion detector of the present application uses high-purity iron to make a thin strip of metal film. When the inside of the anti-rust packaging is damaged and meets the possible conditions for corrosion (certain humidity and oxygen conditions), it can corrode before the internal equipment, issue an alarm or corresponding prompt of the corrosion condition, and give a warning before the equipment or product protected by the anti-rust packaging corrodes, so that the management personnel can take corresponding measures, improve the anti-rust protection performance, and reduce the risk of corrosion. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Hereinafter, some specific embodiments of the present invention will be described in detail in an exemplary and non-limiting manner with reference to the accompanying drawings. The same reference numerals in the accompanying drawings indicate the same or similar components or parts. It should be understood by those skilled in the art that these drawings are not necessarily drawn to scale. In the accompanying drawings: Figure 1 is a schematic diagram of the framework structure of a corrosion early warning system according to an embodiment of the present invention; Figure 2 is a schematic structural diagram of a diaphragm corrosion detector according to an embodiment of the present invention; Figure 3 is based on Figure 1 A schematic diagram of the locally enlarged structure in the diaphragm corrosion detector is shown.

[0019] The following are the descriptions of the reference numerals: 1. Substrate, 2. Metal film layer, 21. Metal film, 3. Guide electrode. DETAILED DESCRIPTION

[0020] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0022] In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other. Example

[0023] This embodiment describes a corrosion early warning system, which includes: Signal acquisition module, used to collect the ambient temperature and humidity, oxygen concentration and corrosion current of the product to be tested; A communication module, connected to the signal acquisition module and communicating with a remote server; and The server receives the data fed back by the signal acquisition module and makes a comprehensive judgment to determine whether there is a corrosion risk in the environment of the product to be tested, and issues an alarm.

[0024] The corrosion warning system of this embodiment combines temperature and humidity, oxygen concentration and corrosion current detection by a new structure corrosion detector to comprehensively realize corrosion detection and improve detection sensitivity. The diaphragm corrosion detector of this application uses high-purity iron to make a thin strip of metal film. When the inside of the anti-rust packaging is damaged and meets the possible conditions for corrosion (certain humidity and oxygen conditions), it can corrode before the internal equipment appears, issue an alarm or corresponding prompt of the corrosion condition, and give a warning before the equipment or product protected by the anti-rust packaging corrodes, which is convenient for management personnel to carry out corresponding treatment, improve the anti-rust protection performance, and reduce the risk of corrosion.

[0025] Specifically, the signal acquisition module includes a temperature and humidity sensor and an oxygen concentration sensor, which are used to collect the ambient temperature, humidity and oxygen concentration of the product to be tested, and send the collected data to the server via the communication module.

[0026] In addition, the signal acquisition module includes a diaphragm corrosion detector, wherein: like Figure 2 As shown, the diaphragm corrosion detector comprises: The substrate 1 is made of a rigid insulating material having good adhesion to iron, such as aluminum oxide; The metal film layer 2 is formed on at least one side of the substrate 1 and arranged in a regular shape; The metal film layer 2 is made of high-purity iron of 2N or above.

[0027] When using a corrosion detector to detect corrosion, the corrosion detector made of measuring materials is installed inside the anti-rust packaging. By measuring the change in potential or current on the surface of the material, it is evaluated whether it has rusted. If rust occurs, it means that the inside of the anti-rust packaging meets the rust conditions and needs to be treated. If the corrosion detector used can corrode before the internal equipment or products, it is undoubtedly possible to carry out corresponding treatment before the equipment or products rust.

[0028] The corrosion detector provided in this embodiment of the present invention can simulate the corrosion performance of the materials of high-precision equipment by using high-purity iron of 2N or above, but it can produce rust changes before the equipment, thereby bringing about changes in potential and current, and then feedback the environmental conditions inside the anti-rust packaging to give anti-rust reminders.

[0029] The metal film 21 is manufactured on the substrate 1 by a magnetron sputtering coating process. The magnetron sputtering coating process utilizes high-energy ions generated by the collision of high-speed electrons with target atoms (using 2N or higher high-purity iron as the target material) to sputter the target atoms from the surface and deposit them on the substrate 1 to form a thin film.

[0030] In addition, the metal film layer 2 can be provided on one side of the substrate 1 or on both sides of the substrate 1. The specific changes can be adjusted according to design requirements and should be protected by this application.

[0031] Specifically, the metal film layer 2 includes a plurality of strip-shaped metal films 21, each of which has a width of 0.1 to 0.2 mm and a thickness of 1 to 2 μm. Since droplets and dust are important factors that induce corrosion, when the size of droplets and dust reaches a certain size, such as 0.1 mm, it becomes the key to the occurrence of corrosion. When the size of droplets or dust reaches or exceeds the spacing between the two metal films 21, it will quickly cause the electrical signal of the metal film layer 2 to change, and the electrical signal will be collected and uploaded in time. In addition, since the metal film 21 is very thin, when corrosion occurs, slight corrosion will also cause a significant change in resistance, which will in turn cause a significant change in the electrical signal, and the electrical signal can be collected and uploaded for alarm. It can be said that the metal film 21 with small spacing and fine lines is also an extremely favorable condition for warning the occurrence of corrosion. It can not only detect the presence of droplets or dust, but also rust and alarm before the protected equipment.

[0032] Optionally, the metal films 21 in the metal film layer 2 are regularly arranged with uniform spacing, the metal films 21 are parallel to each other to form a ring-shaped pattern, and the spacing between the metal films 21 is 0.05-0.15 mm.

[0033] like Figure 3 As shown, the metal film layer 2 includes a plurality of strip-shaped metal films 21, and each metal film 21 is surrounded to form a U-shaped or C-shaped figure. Each metal film 21 is arranged in a tight and regular shape. When powered on, once it comes into contact with water vapor, a potential difference can be generated between adjacent metal films 21 to accelerate corrosion, so that the environmental changes can be better fed back. The minimum monitoring impedance sensitivity of the diaphragm corrosion detector is on the order of uΩ.

[0034] Optionally, when the metal films 21 surround to form a U-shaped pattern, the middle position of the middle connection portion of each metal film 21 has an n-shaped protrusion protruding in the same direction, and the widths of the n-shaped protrusions on two adjacent metal films 21 are arranged in equal intervals. This design enables the metal film 21 to have multiple convex corners, and both the convex corners at the corners of the U-shaped metal film 21 and the convex corners at the corners of the n-shaped protrusions are typical structures for corrosion in this application. Therefore, when corrosion occurs in metal devices, it starts first at the convex corners at the corners. Therefore, the structure with multiple protrusions and multiple convex corners can improve the detection sensitivity. In addition, this symmetrical design can effectively utilize the surface space of the substrate, while maximizing the effective test surface, it is convenient for the external processing circuit to test the current change of the diaphragm corrosion detector, making the measurement process more accurate and improving the detection sensitivity of the diaphragm corrosion detector.

[0035] When the metal film layer 2 in the diaphragm corrosion detector is connected to the external detection and processing circuit, a conductive hole can be set on the substrate 1 to connect the detection and processing circuit through a conductive wire, or one end of the conductive wire can be directly welded to the metal film layer 2 and the other end can be connected to the detection and processing circuit. In addition, a guide electrode 3 can also be set on the substrate 1, and the guide electrode 3 is connected to the metal film layer 2. The thickness or width of the guide electrode 3 can be adjusted as needed, which is convenient for connection with the conductive wire and can further ensure the conductivity reliability, so that the width and thickness of the metal film layer 2 can better meet the design requirements.

[0036] Optionally, the diaphragm corrosion detector also includes a guide electrode 3, which is formed on the same side as the metal film layer 2, and the two ends of the metal film layer 2 are respectively connected to a guide electrode 3, and the guide electrode 3 is used to connect to an external detection and processing circuit. The guide electrode 3 is formed together with the metal film layer 2 on the side of the substrate 1.

[0037] The corrosion early warning system of the present application can be applied to the logistics transportation process or storage packaging of the product to be tested.

[0038] The corrosion early warning system of this application can have the following beneficial effects in the logistics process: 1. During the logistics process, remote backend real-time monitoring can be carried out. If the product packaging is damaged or abnormal, real-time warning can be issued to convey risk information to relevant personnel at the early stage of occurrence, leaving time for subsequent remedial measures; 2. In scenarios where logistics time is long and there is no 4G signal, such as sea transportation, after the product arrives at the destination (with 4G signal), the data will be packaged and uploaded to the server and updated in the background, making it easier to understand the actual situation of the goods packaging; 3. Through data collection and storage, in the event of packaging failure, the time characteristics and causes of packaging failure can be found according to data rules, providing data support for subsequent upgrades and optimizations of packaging; 4. The validity data of packaged products can be traced.

[0039] The corrosion early warning system of the present application can have the following beneficial effects in storage packaging: 1. In the case of product warehousing, if the product packaging fails during the storage process, the abnormal information will be sent to the backend for early warning every 30 minutes to leave time for timely processing of abnormal packaging; 2. When multiple products are stored in the same warehouse, the invalid packaging can be accurately identified, saving time for warehouse managers and basically eliminating product losses caused by packaging failure; 3. An alarm indicator light will be added to the monitoring terminal (this indicator light is a small indicator light to save power) and an interface for the alarm indicator (sound and light alarm, this device consumes more power and requires increased battery capacity). If the product packaging fails, not only will an alarm for data anomalies be provided in the background, but an alarm will also be issued on the monitoring terminal to remind relevant personnel to deal with it as soon as possible. At the same time, the abnormal information will be recorded in the storage and cloud data center for subsequent analysis of the cause. Example

[0040] This invention describes a working method of a corrosion early warning system. The structure of the corrosion early warning system is as described in Example 1. The working method includes the following working steps: The signal acquisition module collects the ambient temperature, humidity and oxygen concentration of the product to be tested at regular intervals, and generates corrosion current through a membrane corrosion detector that can oxidize and corrode; The temperature and humidity signal, oxygen concentration signal and corrosion current signal obtained by the signal acquisition module are sent to the server via the communication module; The server side stores the obtained temperature and humidity signals, oxygen concentration signals and corrosion current signals, and compares the temperature and humidity signals, oxygen concentration signals and corrosion current signals with set thresholds, and issues an alarm if any one of the temperature and humidity signals, oxygen concentration signals and corrosion current signals is greater than the corresponding threshold.

[0041] The signal acquisition module works based on a sleep-and-rewake-up mode. The signal acquisition module wakes up every 30 to 60 minutes, works for 1 to 2 minutes after waking up, collects the temperature and humidity signals, oxygen concentration signals, and corrosion current signals, and interacts with the server to adjust the sleep time or working time.

[0042] Optionally, the server records the initial magnitude of the corrosion current signal and monitors its value change, and issues a first-level alarm when the value change is greater than a preset threshold; The server monitors the temperature and humidity signals and the oxygen concentration signals, and issues a second-level alarm if one of the two is greater than a preset threshold, and determines whether to issue a first-level alarm based on the magnitude of the excess threshold; The level of the first level alarm is higher than that of the second level alarm.

[0043] The corrosion early warning system of the present application can send commands to the signal acquisition module through the server side, such as test stop, data storage, and data upload, and the signal acquisition module can collect and send data such as corrosion current, temperature, humidity, and oxygen concentration to the server side. In addition, two or more signal acquisition modules can be set in the product to be tested to improve the accuracy of the acquisition.

[0044] Specifically, the process of communication and interaction between the server and the signal acquisition module is as follows: After the test stop command is issued, the signal acquisition module enters sleep mode and does not collect or upload data. It waits for the upload command to continue uploading data every half an hour. After the data storage command is issued, the signal acquisition module stores the current value every half an hour and continuously collects data until the corrosion current alarm occurs. When the corrosion current alarm occurs, the corrosion current alarm light flashes on the terminal interface on site. After the test stop command is issued, the acquisition module enters sleep mode and does not collect or upload data, waiting for the upload command to continue uploading data every half an hour.

[0045] In addition, there should be a power-on self-test process on the terminal interface to check the status of each sensor in the signal acquisition module to see if there is any fault. The initial data should be tested, and then instructions should be issued to start working, and data should be uploaded and stored.

[0046] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with this technology to understand the contents of the present invention and implement them accordingly. They cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A corrosion early warning system, characterized in that: include: Signal acquisition module, used to collect the ambient temperature and humidity, oxygen concentration and corrosion current of the product to be tested; A communication module, connected to the signal acquisition module and communicating with a remote server; and The server receives the data fed back by the signal acquisition module and makes a comprehensive judgment to determine whether there is a corrosion risk in the environment of the product to be tested, and issues an alarm.

2. The corrosion early warning system according to claim 1, characterized in that: The signal acquisition module includes a temperature and humidity sensor and an oxygen concentration sensor, which are used to collect the ambient temperature, humidity and oxygen concentration of the product to be tested, and send the collected data to the server via the communication module.

3. The corrosion early warning system according to claim 1, characterized in that: The signal acquisition module includes a diaphragm corrosion detector, wherein: The diaphragm corrosion detector comprises a substrate and a metal film layer, wherein the metal film layer is formed on at least one side of the substrate, and the metal film layer is composed of a plurality of metal films arranged in a regular shape, wherein the metal films are arranged regularly and evenly, and the metal films are parallel to each other to form a ring-shaped pattern, and the spacing between the metal films is 0.05-0.15 mm; The metal film corrodes in an oxygen-containing and humid environment, and generates the corrosion current after power is turned on. The collected corrosion current is sent to the server end via the communication module.

4. The corrosion early warning system according to claim 3, characterized in that: The width of each metal film is 0.1~0.2mm and the thickness is 1~2μm.

5. The corrosion early warning system according to claim 3, characterized in that: The metal film layer is made of high-purity iron of 2N or above.

6. The corrosion early warning system according to any one of claims 3 to 5, characterized in that: The diaphragm corrosion detector also includes a guide electrode, which is formed on the same side as the metal film layer. Both ends of the metal film layer are respectively connected to a guide electrode, and the guide electrode is used to connect to an external detection and processing circuit.

7. The corrosion early warning system according to any one of claims 3 to 5, characterized in that: The minimum monitoring impedance sensitivity of the diaphragm corrosion detector is on the order of uΩ.

8. A working method of the corrosion early warning system according to any one of claims 1 to 7, characterized in that: The following steps are included: The signal acquisition module collects the ambient temperature, humidity and oxygen concentration of the product to be tested at regular intervals, and generates corrosion current through a membrane corrosion detector that can oxidize and corrode; The temperature and humidity signal, oxygen concentration signal and corrosion current signal obtained by the signal acquisition module are sent to the server via the communication module; The server side stores the obtained temperature and humidity signals, oxygen concentration signals and corrosion current signals, and compares the temperature and humidity signals, oxygen concentration signals and corrosion current signals with set thresholds, and issues an alarm if any one of the temperature and humidity signals, oxygen concentration signals and corrosion current signals is greater than the corresponding threshold.

9. The working method according to claim 8, characterized in that: The signal acquisition module works based on a sleep-and-rewake-up mode. The signal acquisition module wakes up every 30 to 60 minutes, works for 1 to 2 minutes after waking up, collects the temperature and humidity signals, oxygen concentration signals, and corrosion current signals, and interacts with the server to adjust the sleep time or working time.

10. The working method according to claim 8, characterized in that: The server records the initial magnitude of the corrosion current signal and monitors its value change, and issues a first-level alarm when the value change is greater than a preset threshold; The server monitors the temperature and humidity signals and the oxygen concentration signals, and issues a second-level alarm if one of the two is greater than a preset threshold, and determines whether to issue a first-level alarm based on the magnitude of the excess threshold; The level of the first level alarm is higher than that of the second level alarm.

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