System and method for monitoring leakage of heat exchanger of radiant tube of annealing furnace

Abstract

The invention relates to a leakage monitoring system and method for a radiant tube heat exchanger of an annealing furnace, and the system comprises a detection unit which is disposed on the surface of the radiant tube heat exchanger and is used for monitoring the working state information of the radiant tube heat exchanger; the data processing unit is used for analyzing the working state information of the radiant tube heat exchanger and judging whether leakage signs exist or not; and the alarm unit is used for sending out a sound-light alarm signal according to an analysis result of the data processing unit when a leakage sign is detected to remind an operator to take measures in time. The detection unit, the data processing unit, the alarm unit, the control unit and the display unit are integrated, the working state of the radiant tube heat exchanger can be monitored in real time, leakage signs can be found in time, corresponding measures are taken, and therefore production efficiency reduction, equipment damage and safety accidents caused by leakage are effectively avoided.

Description

Technical Field

[0001] The invention relates to the technical field of heat exchanger detection, and in particular to a leakage monitoring system and method for a radiant tube heat exchanger of an annealing furnace. Background Art

[0002] In industrial production and energy conversion, annealing furnaces are widely used for heating treatment of metal and alloy materials. In this process, the radiant tube is used as a heating source, and its heat exchange efficiency directly affects the performance and energy utilization of the annealing furnace. In recent years, with the continuous development of manufacturing technology, the working environment of the annealing furnace radiant tube has become increasingly complex, and the risk of pipeline aging and wear has increased, causing a significant increase in the possibility of leakage. Once a leak occurs, it will not only lead to a waste of energy, but may also have a serious impact on the safe and stable operation of the equipment.

[0003] In traditional monitoring methods, leak detection mainly relies on manual inspections and regular checks, which are inefficient and slow to respond. Summary of the invention

[0004] To solve the above problems, an object of the embodiments of the present invention is to provide a system and method for monitoring leakage of a radiant tube heat exchanger in an annealing furnace.

[0005] A leakage monitoring system for an annealing furnace radiant tube heat exchanger, comprising:

[0006] A detection unit, arranged on the surface of the radiant tube heat exchanger, for monitoring the working status information of the radiant tube heat exchanger;

[0007] A data processing unit is used to analyze the working status information of the radiant tube heat exchanger to determine whether there is any sign of leakage;

[0008] The alarm unit is used to send out sound and light alarm signals according to the analysis results of the data processing unit when leakage signs are detected, so as to remind the operator to take timely measures.

[0009] Preferably, the detection unit comprises an infrared thermal imager, a pressure sensor and an acoustic wave detector, which are used to collect temperature, pressure and acoustic wave signals of the radiant tube heat exchanger.

[0010] Preferably, the data processing unit includes a data acquisition module, a data storage module and a data analysis module; the data acquisition module is used to collect the working status information of the radiant tube heat exchanger transmitted by the detection unit; the data storage module is used to store the collected working status information; the data analysis module is used to process and analyze the stored data to determine whether there are signs of leakage.

[0011] Preferably, it further comprises: a control unit for automatically adjusting the working state of the radiant tube heat exchanger according to the analysis result of the data processing unit to control the leakage of the radiant tube heat exchanger.

[0012] Preferably, it also includes: a display unit for displaying monitoring data and leakage conditions in real time, so that operators can understand the current status.

[0013] The present invention also provides a method for monitoring leakage of a radiant tube heat exchanger of an annealing furnace, comprising:

[0014] Collecting working status information of the radiant tube heat exchanger; the working status information includes: temperature, pressure and sound wave signal of the radiant tube heat exchanger;

[0015] When any of the temperature, pressure and sound wave of the radiant tube heat exchanger exceeds the threshold, an abnormal alarm signal is issued.

[0016] The present invention also provides an electronic device, comprising a bus, a transceiver, a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the transceiver, the memory and the processor are connected via the bus, and wherein the computer program, when executed by the processor, implements the steps in the above-mentioned method for monitoring leakage of a radiant tube heat exchanger in an annealing furnace.

[0017] The present invention also provides a computer-readable storage medium having a computer program stored thereon, characterized in that when the computer program is executed by a processor, the steps in the above-mentioned method for monitoring leakage of a radiant tube heat exchanger in an annealing furnace are implemented.

[0018] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0019] The present invention relates to a leakage monitoring system and method for a radiant tube heat exchanger of an annealing furnace. Compared with the prior art, the present invention integrates a detection unit, a data processing unit, an alarm unit, a control unit and a display unit, and can monitor the working status of the radiant tube heat exchanger in real time, promptly discover leakage signs, and take corresponding measures, thereby effectively avoiding reduced production efficiency, equipment damage and safety accidents caused by leakage.

[0020] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, preferred embodiments are given below and described in detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0022] Figure 1 A schematic diagram of a leakage monitoring system for a radiant tube heat exchanger of an annealing furnace provided by the present invention;

[0023] Figure 2 A flow chart of a leakage monitoring method for a radiant tube heat exchanger of an annealing furnace provided by the present invention. DETAILED DESCRIPTION

[0024] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0025] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0026] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0027] See also Figure 1 , a leakage monitoring system for an annealing furnace radiant tube heat exchanger, comprising:

[0028] A detection unit is arranged on the surface of the radiant tube heat exchanger and is used to monitor the working status information of the radiant tube heat exchanger; the detection unit includes an infrared thermal imager, a pressure sensor and an acoustic wave detector, which are used to collect the temperature, pressure and acoustic wave signals of the radiant tube heat exchanger;

[0029] A data processing unit is used to analyze the working status information of the radiant tube heat exchanger to determine whether there is a sign of leakage; the data processing unit includes a data acquisition module, a data storage module and a data analysis module; the data acquisition module is used to collect the working status information of the radiant tube heat exchanger transmitted by the detection unit; the data storage module is used to store the collected working status information; the data analysis module is used to process and analyze the stored data to determine whether there is a sign of leakage;

[0030] The alarm unit is used to send out sound and light alarm signals according to the analysis results of the data processing unit when leakage signs are detected, so as to remind the operator to take timely measures.

[0031] Furthermore, the present invention also includes: a control unit, which is used to automatically adjust the working state of the radiant tube heat exchanger according to the analysis result of the data processing unit to control the leakage of the radiant tube heat exchanger. A display unit, which is used to display the monitoring data and leakage situation in real time, so that the operator can understand the current state.

[0032] See also Figure 2 The present invention also provides a method for monitoring leakage of a radiant tube heat exchanger of an annealing furnace, comprising:

[0033] Collecting working status information of the radiant tube heat exchanger; the working status information includes: temperature, pressure and sound wave signal of the radiant tube heat exchanger;

[0034] When any of the temperature, pressure and sound wave of the radiant tube heat exchanger exceeds the threshold, an abnormal alarm signal is issued.

[0035] The present invention integrates a detection unit, a data processing unit, an alarm unit, a control unit and a display unit, and can monitor the working status of the radiant tube heat exchanger in real time, promptly discover signs of leakage, and take corresponding measures, thereby effectively avoiding reduced production efficiency, equipment damage and safety accidents caused by leakage.

[0036] The present invention further describes a leakage monitoring system for annealing furnace radiant tube heat exchanger in combination with specific embodiments of the present invention.

[0037] Embodiment 1: Leakage monitoring system for annealing furnace radiation tube heat exchanger, such as Figure 1As shown, it includes a detection unit, a data processing unit, an alarm unit, a control unit and a display unit. The detection unit is responsible for real-time monitoring of the working state of the radiant tube heat exchanger, and collects various parameter information through sensors installed on the surface of the radiant tube heat exchanger. The detection unit includes an infrared thermal imager, a pressure sensor and an acoustic wave detector, which are used to collect temperature, pressure and acoustic wave parameter information of the radiant tube heat exchanger. By integrating the detection unit, the data processing unit, the alarm unit, the control unit and the display unit, it is possible to monitor the working state of the radiant tube heat exchanger in real time, detect leakage signs in time, and take corresponding measures, thereby effectively avoiding the reduction of production efficiency, equipment damage and safety accidents caused by leakage, ensuring the heating power and safe production of the radiant tube, avoiding affecting the exhaust gas emission system, increasing the service life of the radiant tube and the exhaust gas heat exchanger, shortening the time of hot air pipe burning, and increasing the production capacity of the furnace.

[0038] Embodiment 2: Based on Embodiment 1, Figure 1 As shown, the data processing unit analyzes the collected data to determine whether there is a sign of leakage. The data processing unit includes a data acquisition module, a data storage module and a data analysis module. The data acquisition module is used to collect real-time data from the sensor, the data storage module is responsible for storing the collected data, and the data analysis module processes and analyzes the stored data to determine whether there is a sign of leakage. By adopting advanced monitoring technology, early detection and rapid response to leakage of radiant tube heat exchangers are achieved, greatly reducing production losses and maintenance costs caused by leakage.

[0039] Embodiment 3: Based on Embodiment 1 and Embodiment 2, Figure 1 As shown in the figure, the alarm unit sends out an audible and visual alarm signal when a leak is detected based on the analysis results of the data processing unit, reminding the operator to take timely measures. The alarm unit includes an audible and visual alarm and a remote alarm module. Through real-time monitoring and data analysis, the operator is provided with accurate information on the leak location and extent, making maintenance work more efficient and targeted.

[0040] Embodiment 4: Based on Embodiment 1, Embodiment 2 and Embodiment 3, Figure 1 As shown, the control unit automatically adjusts the working state of related equipment according to the analysis results of the data processing unit to reduce the impact of leakage. The control unit includes a control module and an actuator. The control module is used to receive instructions from the data processing unit, and the actuator is used to adjust the working state of the equipment according to the instructions. The display unit is used to display the monitoring data and leakage situation in real time to facilitate the operator to understand the current state. The display unit includes a display screen and a user interface.

[0041] Embodiment 5: Based on Embodiment 1, Embodiment 2, Embodiment 3 and Embodiment 4, Figure 2 As shown, the implementation method of the annealing furnace radiant tube heat exchanger leakage monitoring includes the above-mentioned annealing furnace radiant tube heat exchanger leakage monitoring system, which specifically includes the following steps: Step 1: Real-time monitoring: The infrared thermal imager in the detection unit performs real-time temperature monitoring on the surface of the radiant tube heat exchanger, and preliminarily determines whether there is a leak by abnormal changes in temperature distribution. The pressure sensor continuously monitors the pressure changes inside the radiant tube heat exchanger. Any abnormal pressure fluctuations may indicate the occurrence of a leak. The acoustic wave detector focuses on capturing abnormal acoustic wave signals that may be generated by a leak, which can usually be detected in the early stages of a leak; Step 2: Data processing: When the data collected by the detection unit is transmitted to the data processing unit, the data acquisition module first performs a preliminary screening and sorting of the data, and then the data storage module saves the data for subsequent analysis and historical data comparison. The data analysis module uses advanced algorithms to conduct in-depth analysis of the data, and determines whether there is a sign of leakage by comparing the set threshold. If the temperature data suddenly rises or the pressure data fluctuates abnormally, the data analysis module will issue an alarm signal; Step 3: Abnormal alarm: After receiving the leakage sign signal from the data processing unit, the alarm unit will immediately start the sound and light alarm to sound the alarm, and at the same time send the alarm information to the operator's mobile device or control center through the remote alarm module to ensure that the operator can take timely measures. In addition, the alarm unit can also notify relevant personnel by email or text message to ensure timely transmission of information; Step 4: Adjust the working state of the equipment: The control unit automatically or manually adjusts the working state of the relevant equipment according to the analysis results of the data processing unit. For example, the control module can issue instructions to the actuator to adjust the cooling water flow, gas flow or air flow of the radiant tube heat exchanger to reduce the impact of the leakage. In some cases, the control unit can also automatically close the leaking radiant tube to prevent further damage; Step 5: Real-time display: The display unit displays the monitoring data and leakage situation in real time. The operator can view the current temperature, pressure, sound wave parameters and leakage situation through the user interface to make corresponding operation decisions. The display unit can also provide a historical data query function to help the operator analyze the trend and cause of the leakage, so as to take more effective preventive measures.

[0042] The working principle of the present invention is as follows: first, an infrared thermal imager, a pressure sensor and an acoustic wave detector in the detection unit need to be installed at an appropriate position of the radiant tube heat exchanger. The infrared thermal imager is used to monitor the temperature distribution on the surface of the radiant tube heat exchanger in real time, the pressure sensor is used to monitor the pressure changes inside the radiant tube heat exchanger, and the acoustic wave detector is used to capture abnormal acoustic wave signals that may be generated by leakage. These sensors transmit the data collected in real time to the data processing unit. The data acquisition module in the data processing unit is responsible for receiving the real-time data from the detection unit and transmitting it to the data storage module for storage. The data analysis module analyzes the stored data and determines whether there is a sign of leakage through a specific algorithm. For example, the data analysis module can set the thresholds of temperature, pressure and acoustic wave parameters. Once data beyond the normal range is detected, it is considered that there is a possibility of leakage. After receiving the leakage sign signal sent by the data processing unit, the alarm unit will start the sound and light alarm to sound an alarm, and send the alarm information to the operator's mobile device or control center through the remote alarm module so that timely measures can be taken. The control unit automatically adjusts the working state of the relevant equipment according to the analysis results of the data processing unit. For example, the control module can issue instructions to the actuator to adjust the cooling water flow, gas flow or air flow of the radiant tube heat exchanger to reduce the impact of leakage. The display unit displays the monitoring data and leakage in real time. The operator can view the current temperature, pressure, acoustic wave parameters and leakage through the user interface to make corresponding operational decisions.

[0043] The present invention also provides an electronic device, comprising a bus, a transceiver, a memory, a processor and a computer program stored in the memory and executable on the processor, wherein the transceiver, the memory and the processor are connected via the bus, and is characterized in that when the computer program is executed by the processor, the steps in the above-mentioned annealing furnace radiant tube heat exchanger leakage monitoring system are implemented. Compared with the prior art, the beneficial effects of the electronic device provided by the present invention are the same as the beneficial effects of the annealing furnace radiant tube heat exchanger leakage monitoring method described in the above-mentioned technical solution, which will not be elaborated here.

[0044] The present invention also provides a computer-readable storage medium having a computer program stored thereon, characterized in that when the computer program is executed by a processor, the steps in the above-mentioned annealing furnace radiant tube heat exchanger leakage monitoring system are implemented. Compared with the prior art, the beneficial effects of the computer-readable storage medium provided by the present invention are the same as the beneficial effects of the annealing furnace radiant tube heat exchanger leakage monitoring method described in the above-mentioned technical solution, which will not be repeated here.

[0045] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any technical solution that can be easily thought of by a person skilled in the art within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. An annealing furnace radiant tube heat exchanger leakage monitoring system, characterized in that: include: A detection unit, arranged on the surface of the radiant tube heat exchanger, for monitoring the working status information of the radiant tube heat exchanger; A data processing unit is used to analyze the working status information of the radiant tube heat exchanger to determine whether there is any sign of leakage; The alarm unit is used to send out sound and light alarm signals according to the analysis results of the data processing unit when leakage signs are detected, so as to remind the operator to take timely measures.

2. The annealing furnace radiant tube heat exchanger leakage monitoring system according to claim 1, characterized in that: The detection unit comprises an infrared thermal imager, a pressure sensor and an acoustic wave detector, and is used for collecting temperature, pressure and acoustic wave signals of the radiation tube heat exchanger.

3. The annealing furnace radiant tube heat exchanger leakage monitoring system according to claim 1, characterized in that: The data processing unit includes a data acquisition module, a data storage module and a data analysis module; the data acquisition module is used to collect the working status information of the radiant tube heat exchanger transmitted by the detection unit; the data storage module is used to store the collected working status information; the data analysis module is used to process and analyze the stored data to determine whether there is any sign of leakage.

4. The annealing furnace radiant tube heat exchanger leakage monitoring system according to claim 3, characterized in that: Also includes: The control unit is used to automatically adjust the working state of the radiant tube heat exchanger according to the analysis result of the data processing unit to control the leakage of the radiant tube heat exchanger.

5. The annealing furnace radiant tube heat exchanger leakage monitoring system according to claim 1, characterized in that: Also includes: The display unit is used to display monitoring data and leakage conditions in real time, making it easier for operators to understand the current status.

6. A method for monitoring leakage of a radiant tube heat exchanger in an annealing furnace, characterized in that: include: Collect working status information of radiant tube heat exchanger; The working status information includes: temperature, pressure and sound wave signal of the radiant tube heat exchanger; When any of the temperature, pressure and sound wave of the radiant tube heat exchanger exceeds the threshold, an abnormal alarm signal is issued.

7. An electronic device, comprising a bus, a transceiver, a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the transceiver, the memory, and the processor are connected via the bus, wherein: When the computer program is executed by the processor, the steps of the method for monitoring leakage of a radiant tube heat exchanger in an annealing furnace as claimed in claim 6 are implemented.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for monitoring leakage of a radiant tube heat exchanger in an annealing furnace as claimed in claim 6 are implemented.

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