Method for monitoring operation state of metal smelting equipment

Abstract

The invention provides a method for monitoring the running state of metal smelting equipment, and the method comprises the steps: arranging distributed optical fiber sensors in a furnace wall high-temperature region and a pipeline elbow key region of a to-be-monitored structure, and enabling the distributed optical fiber sensors to be in close contact with the structure; pulse light or continuous wave light is transmitted to a sensor through an optical fiber sensing system, and temperature and strain information carried by a backscattered light signal is received; the signals are demodulated by adopting technologies such as time domain reflection and the like, and the data accuracy is improved through digital filtering, signal amplification and data calibration; according to the extracted data, in combination with structural physical characteristics and a threshold model based on multi-parameter and SVM dynamic adjustment, when monitoring data exceeds a threshold, triggering an alarm and generating an abnormal report; according to the invention, comprehensive and accurate monitoring of key parts of the metal smelting equipment is realized, data can be flexibly and efficiently acquired, intelligent early warning is timely, and safe and stable operation of the equipment is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of metal smelting equipment monitoring, and in particular to a method for monitoring the operating status of metal smelting equipment. Background Art

[0002] Metal smelting equipment operates under extreme conditions such as high temperature, high pressure, and strong corrosion for a long time. Its key components such as furnace linings, bearings, and transmission shafts are prone to performance degradation or even sudden failures due to material fatigue, thermal stress accumulation, and chemical erosion. Traditional monitoring methods mainly rely on single sensor data, such as temperature or vibration threshold alarms and regular manual inspections, which have significant limitations: On the one hand, traditional monitoring methods often rely on regular manual inspections, which is not only inefficient but also difficult to achieve real-time monitoring. Due to the long time intervals between manual inspections, subtle abnormalities that occur during equipment operation may not be discovered in time, causing problems to gradually accumulate, which may eventually lead to serious equipment failures and even production accidents, causing huge economic losses and safety hazards to the company.

[0003] On the other hand, the existing partially automated monitoring systems have limitations in data collection and analysis. They can only collect some key parameters of equipment operation, and cannot conduct comprehensive and in-depth monitoring and analysis of some complex states and potential problems in the equipment operation process. For example, for some equipment's dynamic changing parameters such as vibration and temperature distribution, the existing monitoring system may not be able to accurately capture and analyze them, and thus cannot provide early warning of possible equipment failures. Therefore, a monitoring method for the operating status of metal smelting equipment is proposed. Summary of the invention

[0004] In view of this, the present invention provides a method for monitoring the operating status of metal smelting equipment to solve or alleviate the technical problems existing in the prior art and at least provide a beneficial option.

[0005] The technical solution of the present invention is implemented as follows: a method for monitoring the operating status of metal smelting equipment, the monitoring method comprising the following steps: S1. Distributed optical fiber sensors are arranged on the structure to be monitored. The optical fiber sensors are laid continuously or in sections along the length direction of the structure to be monitored. The key monitoring areas are the high-temperature area of ​​the furnace wall of the furnace body and the elbow of the pipeline where the temperature or strain changes in the structure to be monitored have a greater impact on the safe operation of the equipment. The optical fiber sensors are in close contact with the structure to be monitored through a coupling agent or an adhesive layer. By arranging distributed optical fiber sensors on the structure to be monitored and laying them in key monitoring areas such as the high-temperature area of ​​the furnace wall of the furnace body and the elbow of the pipeline, comprehensive monitoring of the temperature and strain of key parts of the metal smelting equipment can be achieved; the distributed optical fiber sensors are laid continuously or in sections along the length direction of the structure to be monitored, and are in close contact with the structure to be monitored through a coupling agent or an adhesive layer, ensuring that the sensors can accurately sense subtle changes in the structure; S2. Transmitting an optical signal to the distributed optical fiber sensor through an optical fiber sensing system, wherein the optical signal adopts pulsed light or continuous wave light, wherein pulsed light is suitable for rapidly acquiring distributed data, and continuous wave light is suitable for high-precision measurement, and receiving temperature and strain information carried by the backscattered light signal in the optical fiber, transmitting pulsed light or continuous wave light to the distributed optical fiber sensor through an optical fiber sensing system, wherein pulsed light is suitable for rapidly acquiring distributed data, and continuous wave light is suitable for high-precision measurement, and the appropriate optical signal type can be flexibly selected according to different monitoring requirements, thereby improving the efficiency and flexibility of data acquisition, and enabling the monitoring method to adapt to the requirements of different operation stages and different monitoring scenarios of metal smelting equipment; S3, demodulating the received backscattered light signal by using at least one of time domain reflection technology, frequency domain analysis technology or phase sensitive optical time domain reflection technology; The demodulation process includes using a digital filter to filter out noise, using a signal amplification circuit to enhance the signal, and calibrating the data according to a preset calibration algorithm. During the demodulation process, a digital filter is used to filter out noise from the signal, and appropriate filtering parameters are set to effectively remove high-frequency noise and interference signals in the signal. The filtered signal is then enhanced by the signal amplification circuit to improve the signal strength and signal-to-noise ratio. The data is then calibrated according to a preset calibration algorithm. The calibration algorithm is established based on a large amount of experimental data and theoretical analysis, and targeted calibration is performed on different types of optical fiber sensors and monitoring environments to ensure that the demodulated data accurately reflects the temperature and strain of the structure to be monitored. S4. Based on the extracted temperature and strain data, combined with the physical characteristics of the structure to be monitored and the preset threshold model, the threshold model is dynamically adjusted using a support vector machine (SVM) based on historical monitoring data, structural design parameters, material performance parameters and operating experience. When the monitoring data exceeds the preset threshold, an alarm mechanism is triggered and an abnormality report is generated.

[0006] Further preferably, the distributed optical fiber sensor adopts at least one of a Brillouin scattering type, a Raman scattering type or a Rayleigh scattering type optical fiber sensor; Brillouin scattering optical fiber sensors can accurately measure temperature and strain with high measurement accuracy and good resolution of temperature and strain. They are suitable for key parts of metal smelting equipment with high monitoring accuracy requirements and can accurately capture tiny temperature and strain changes during equipment operation. Raman scattering optical fiber sensor has a wide measurement range and fast response speed. It can perform real-time monitoring in a large temperature and strain range. It can quickly respond to the rapid changes in temperature and strain during the operation of metal smelting equipment and reflect the operating status of the equipment in a timely manner. Rayleigh scattering optical fiber sensor has strong distributed measurement capability and can realize long-distance continuous monitoring. It can cover a large range of monitored structures in metal smelting equipment and comprehensively obtain the operating status information of the equipment.

[0007] Further preferably, the coupling agent or adhesive layer is made of epoxy resin-based composite material, which is made by mixing epoxy resin, curing agent, toughening agent and filler in proportion, wherein the mass ratio of epoxy resin to curing agent is 100:(20-30), the amount of toughening agent added is 5%-15% of the mass of epoxy resin, and the filler is nano-silicon dioxide particles, and the amount of which added is 1%-5% of the mass of epoxy resin; The mass ratio of epoxy resin to curing agent can ensure that the composite material has good bonding performance and mechanical strength after curing, so that the optical fiber sensor is closely combined with the structure to be monitored, ensuring the stability of signal transmission; The amount of toughening agent added is 5%-15% of the mass of epoxy resin, which effectively improves the toughness of the composite material and reduces the cracking or damage of the material caused by vibration and temperature changes during the operation of metal smelting equipment; The addition amount of nano-silicon dioxide particles is 1%-5% of the mass of epoxy resin, which can enhance the hardness, wear resistance and corrosion resistance of the composite material.

[0008] Further preferably, the optical fiber sensing system further comprises a temperature compensation module, which measures the ambient temperature in real time through a built-in temperature sensor, wherein the temperature sensor adopts a platinum resistance temperature sensor with a measurement accuracy of ±0.5°C, and performs temperature compensation on the measurement data of the optical fiber sensor; The platinum resistance temperature sensor has a measurement accuracy of ±0.5°C and can accurately measure the ambient temperature. By performing temperature compensation on the measurement data of the optical fiber sensor, the influence of ambient temperature changes on the measurement results can be eliminated. During the operation of metal smelting equipment, the ambient temperature fluctuates greatly. The temperature compensation module can ensure that the monitoring data truly reflects the operating status of the equipment and avoid misjudgment due to temperature interference.

[0009] Further preferably, the monitoring method also includes data storage and management, and the data storage and management adopt a distributed database system, realize efficient data query and retrieval through data index structure and query algorithm, and adopt redundant backup and encryption technology.

[0010] Further preferably, the monitoring method is used for operating status monitoring of key components of furnaces, pipelines, reactors or storage tanks in metal smelting equipment, and by performing long-term analysis and trend prediction on the extracted temperature and strain data, an early warning signal is issued when potential risks to the structure are predicted.

[0011] Further preferably, the optical fiber sensing system transmits the monitoring data to the remote monitoring center in real time through 5G communication technology or Ethernet communication technology. 5G communication technology and Ethernet communication technology have high-speed and stable transmission characteristics, and can realize real-time transmission of monitoring data, so that the remote monitoring center can obtain the operating status information of the metal smelting equipment in time and make a quick response.

[0012] Further preferably, the monitoring method further comprises a periodic calibration step, wherein the periodic calibration step is performed in a cycle of every 30 days or every 100 working hours, and the optical fiber sensor and optical fiber sensing are calibrated using a standard temperature source and a strain source.

[0013] Further preferably, the distributed optical fiber sensors are laid in a dense manner in key monitoring areas, that is, in the key monitoring areas of the high-temperature area of ​​the furnace wall and the elbow of the pipeline, the laying spacing of the optical fiber sensors is smaller than that of the non-critical monitoring areas, and the densely laid optical fiber sensors and the non-encrypted laid optical fiber sensors are continuously transmitted through wireless signals.

[0014] Further preferably, after emitting an optical signal to the distributed optical fiber sensor through the optical fiber sensing system and receiving the temperature and strain information carried by the backscattered light signal in the optical fiber, a wavelet transform algorithm is used to denoise the received backscattered light signal to remove high-frequency noise and low-frequency drift in the backscattered light signal.

[0015] The embodiment of the present invention has the following advantages due to the adoption of the above technical solution: 1. The monitoring method of the present invention arranges distributed optical fiber sensors on the structure to be monitored, and focuses on laying them in key monitoring areas such as the high-temperature area of ​​the furnace wall of the furnace body and the elbows of the pipeline, so as to achieve comprehensive monitoring of the temperature and strain of key parts of metal smelting equipment; the distributed optical fiber sensors are laid continuously or in sections along the length direction of the structure to be monitored, and are in close contact with the structure to be monitored through a coupling agent or an adhesive layer, which ensures that the sensors can accurately sense subtle changes in the structure. Compared with traditional monitoring methods that can only obtain some key parameters, this method can obtain more comprehensive equipment operation information, greatly improve the accuracy of monitoring, and help to timely discover potential problems in the equipment operation process.

[0016] 2. The present invention transmits pulse light or continuous wave light to distributed optical fiber sensors through an optical fiber sensing system. Pulse light is suitable for quickly acquiring distributed data, and continuous wave light is suitable for high-precision measurement. The appropriate optical signal type can be flexibly selected according to different monitoring needs, thereby improving the efficiency and flexibility of data acquisition. This flexibility enables the monitoring method to adapt to the requirements of different operating stages and different monitoring scenarios of metal smelting equipment, whether it is necessary to quickly understand the overall operating status of the equipment or to conduct high-precision local monitoring, it can be effectively achieved.

[0017] The above summary is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments and features described above, further aspects, embodiments and features of the present invention will be readily apparent by reference to the accompanying drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present application 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 application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0019] Figure 1 It is a step diagram of the monitoring method of the present invention. DETAILED DESCRIPTION

[0020] In the following, only some exemplary embodiments are briefly described. As those skilled in the art will appreciate, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and descriptions are considered to be exemplary and non-restrictive in nature.

[0021] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0022] like Figure 1As shown, an embodiment of the present invention provides a method for monitoring the operating status of metal smelting equipment, characterized in that the monitoring method comprises the following steps: S1. The sensors are arranged as follows: In this embodiment, the key monitoring area is accurately determined on the metal smelting equipment to be monitored. This area is the part of the equipment where the temperature or strain change has a significant impact on safe operation. The high-temperature area of ​​the furnace wall of the furnace body is subjected to high temperature for a long time and the temperature change gradient is large, and the elbow part of the pipeline is prone to large strain due to fluid impact and temperature change. Therefore, according to the actual shape and size of the structure to be monitored, the distributed optical fiber sensor is laid continuously or in sections along its length. If the structure is relatively regular and needs to be fully monitored, continuous laying is adopted to ensure that every subtle temperature and strain change can be captured; if the structure is complex or only specific parts need to be monitored, segmented laying is adopted to concentrate the sensors in key positions. The selected distributed optical fiber sensor is at least one of Brillouin scattering, Raman scattering or Rayleigh scattering optical fiber sensors. Different types of sensors are suitable for different monitoring scenarios. Brillouin scattering sensors have higher accuracy in strain monitoring. The optical fiber sensor is in close contact with the structure to be monitored through a coupling agent or adhesive layer. The coupling agent or adhesive layer uses an epoxy resin-based composite material, and its material is a mixture of epoxy resin, curing agent, toughening agent and nano-silica particle filler in proportion. The specific ratio is that the mass ratio of epoxy resin to curing agent is 100:(20-30), the amount of toughening agent added is 5%-15% of the mass of epoxy resin, and the amount of nano-silica particle filler added is 1%-5% of the mass of epoxy resin. When preparing, first mix the epoxy resin and curing agent in proportion, stir for 10-15 minutes at a temperature of 30℃-40℃, then add the toughening agent and nano-silica particles in turn, and continue stirring for 20-30 minutes until a uniform, bubble-free colloidal substance is formed, and then evenly apply it on the contact surface between the optical fiber sensor and the structure to be monitored to ensure that the two are tightly combined.

[0023] S2. Signal transmission and reception In this embodiment, an optical signal is transmitted to a distributed optical fiber sensor through an optical fiber sensing system. The type of optical signal is selected according to the monitoring requirements. If distributed data needs to be quickly acquired and the status of multiple parts needs to be understood in real time in large-scale equipment monitoring, pulsed light is used; if high-precision measurement is required to accurately monitor the tiny temperature or strain changes of key components, continuous wave light is used. The emitted light signal is transmitted to the sensor via the optical fiber, where it is backscattered. The backscattered light signal carrying temperature and strain information is received by the optical fiber sensing system. At the same time, the optical fiber sensing system is equipped with a temperature compensation module. The temperature compensation module has a built-in platinum resistance temperature sensor with a measurement accuracy of ±0.5°C. The temperature sensor measures the ambient temperature in real time and transmits the measurement data to the temperature compensation module. The module performs temperature compensation on the measurement data of the optical fiber sensor based on a preset compensation algorithm to eliminate measurement errors caused by changes in ambient temperature and ensure that the acquired temperature and strain data are accurate and reliable.

[0024] S3. Signal demodulation The received backscattered light signal is demodulated and processed, and at least one of the time domain reflection technology, frequency domain analysis technology or phase sensitive optical time domain reflection technology is used. The time domain reflection technology determines the position of the scattering point by analyzing the time delay of the light signal transmitted in the optical fiber, thereby obtaining the temperature and strain information distributed along the optical fiber; the frequency domain analysis technology analyzes the frequency characteristics of the light signal and extracts the frequency components related to temperature and strain; the phase sensitive optical time domain reflection technology uses the phase change of the light signal to accurately measure the temperature and strain; During the demodulation process, a digital filter is used to filter out noise from the signal. Appropriate filtering parameters are set to effectively remove high-frequency noise and interference signals in the signal. The filtered signal is then enhanced through a signal amplification circuit to improve signal strength and signal-to-noise ratio. The data is then calibrated based on a preset calibration algorithm. The calibration algorithm is established based on a large amount of experimental data and theoretical analysis, and targeted calibration is performed on different types of fiber optic sensors and monitoring environments to ensure that the demodulated data accurately reflects the temperature and strain of the structure to be monitored.

[0025] S4. Data analysis and alarm According to the temperature and strain data extracted after demodulation, combined with the thermal expansion coefficient and elastic modulus of the material of the structure to be monitored, and the preset threshold model, the analysis is carried out. The threshold model is comprehensively established based on historical monitoring data, structural design parameters, material performance parameters and operating experience, and is dynamically adjusted using support vector machine SVM; SVM constructs a classification hyperplane by learning and analyzing a large amount of historical data, and effectively distinguishes data in normal and abnormal states. When the monitoring data exceeds the preset threshold, the system immediately triggers the alarm mechanism, reminding relevant personnel through sound and light alarms and SMS notifications, and at the same time, generates a detailed abnormality report.

[0026] In this embodiment, the monitoring method also includes data storage and management. The data storage and management adopt a distributed database system, and efficient data query and retrieval are achieved through data index structure and query algorithm, while redundant backup and encryption technology are adopted.

[0027] In this embodiment, the monitoring method is used to monitor the operating status of key components of the furnace, pipeline, reactor or storage tank in metal smelting equipment. By performing long-term analysis and trend prediction on the extracted temperature and strain data, an early warning signal is issued in advance when potential risks are predicted in the structure.

[0028] In this embodiment, the fiber optic sensing system transmits the monitoring data to the remote monitoring center in real time through 5G communication technology or Ethernet communication technology.

[0029] In this embodiment, the monitoring method further includes a periodic calibration step, which is performed every 30 days or every 100 working hours, and uses a standard temperature source and a strain source to calibrate the optical fiber sensor and the optical fiber sensing.

[0030] In this embodiment, the distributed optical fiber sensors are laid in a dense manner in key monitoring areas, that is, in the key monitoring areas of the high-temperature area of ​​the furnace wall and the elbow of the pipeline, the laying spacing of the optical fiber sensors is smaller than that of the non-critical monitoring areas, and the densely laid optical fiber sensors and the non-encrypted laid optical fiber sensors are continuously transmitted through wireless signals.

[0031] In this embodiment, after transmitting an optical signal to a distributed optical fiber sensor through an optical fiber sensing system and receiving the temperature and strain information carried by the backscattered light signal in the optical fiber, a wavelet transform algorithm is used to denoise the received backscattered light signal to remove high-frequency noise and low-frequency drift in the backscattered light signal.

[0032] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of various changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A method for monitoring the operating status of metal smelting equipment, characterized in that: The monitoring method comprises the following steps: S1. Distributed optical fiber sensors are arranged on the structure to be monitored. The optical fiber sensors are laid continuously or in sections along the length direction of the structure to be monitored. The key monitoring areas are the high-temperature areas of the furnace wall and the elbows of the pipeline where the temperature or strain changes in the structure to be monitored have a greater impact on the safe operation of the equipment. The optical fiber sensors are in close contact with the structure to be monitored through a coupling agent or an adhesive layer. S2. Transmitting an optical signal to the distributed optical fiber sensor through an optical fiber sensing system, wherein the optical signal adopts pulsed light or continuous wave light, wherein pulsed light is suitable for quickly acquiring distributed data, and continuous wave light is suitable for high-precision measurement, and receiving temperature and strain information carried by the backscattered light signal in the optical fiber; S3, demodulating the received backscattered light signal by using at least one of time domain reflection technology, frequency domain analysis technology or phase sensitive optical time domain reflection technology; The demodulation process includes using a digital filter to filter out noise, using a signal amplification circuit to enhance the signal, and calibrating the data according to a preset calibration algorithm; S4. Based on the extracted temperature and strain data, combined with the physical characteristics of the structure to be monitored and the preset threshold model, the threshold model is dynamically adjusted using a support vector machine (SVM) based on historical monitoring data, structural design parameters, material performance parameters and operating experience. When the monitoring data exceeds the preset threshold, an alarm mechanism is triggered and an abnormality report is generated.

2. A method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The distributed optical fiber sensor adopts at least one of Brillouin scattering, Raman scattering or Rayleigh scattering optical fiber sensors.

3. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The coupling agent or adhesive layer adopts an epoxy resin-based composite material, which is made by mixing epoxy resin, curing agent, toughening agent and filler in proportion, wherein the mass ratio of epoxy resin to curing agent is 100:(20-30), the added amount of toughening agent is 5%-15% of the mass of epoxy resin, and the filler is nano-silicon dioxide particles, and the added amount is 1%-5% of the mass of epoxy resin.

4. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The optical fiber sensing system also includes a temperature compensation module, which measures the ambient temperature in real time through a built-in temperature sensor. The temperature sensor uses a platinum resistance temperature sensor with a measurement accuracy of ±0.5°C, and performs temperature compensation on the measurement data of the optical fiber sensor.

5. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The monitoring method also includes data storage and management, which uses a distributed database system to achieve efficient data query and retrieval through a data index structure and a query algorithm.

6. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The monitoring method is used for monitoring the operating status of key components of furnaces, pipelines, reactors or storage tanks in metal smelting equipment by performing long-term analysis and trend prediction on the extracted temperature and strain data.

7. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The optical fiber sensing system transmits the monitoring data to the remote monitoring center in real time through 5G communication technology or Ethernet communication technology.

8. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The monitoring method further comprises a periodic calibration step, which is performed every 30 days or every 100 working hours, and uses a standard temperature source and a strain source to calibrate the optical fiber sensor and the optical fiber sensing.

9. A method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: The laying method of the distributed optical fiber sensors adopts encrypted laying in key monitoring areas, that is, in the key monitoring areas of the high-temperature area of ​​the furnace wall of the furnace body and the elbow part of the pipeline, the laying spacing of the optical fiber sensors is smaller than that of the non-critical monitoring areas, and the encrypted laid optical fiber sensors and the non-encrypted laid optical fiber sensors are continuously transmitted through wireless signals.

10. The method for monitoring the operating status of metal smelting equipment according to claim 1, characterized in that: After transmitting an optical signal to the distributed optical fiber sensor through the optical fiber sensing system and receiving the temperature and strain information carried by the backscattered light signal in the optical fiber, a wavelet transform algorithm is used to denoise the received backscattered light signal and remove high-frequency noise and low-frequency drift in the backscattered light signal.

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