Dust remover structure monitoring system and method

Abstract

The invention relates to the field of dust remover structure monitoring, in particular to a dust remover structure monitoring system and method.The dust remover structure monitoring system comprises a detection module arranged on a dust remover, a data processing module connected with the detection module, an upper computer and a stress health monitoring module which are connected with the data processing module, and a prompt module connected with the upper computer; and the detection module transmits the signal to the data processing module, and the data processing module analyzes and processes the data and displays the result on the upper computer. When abnormal signals are detected, the data processing module sends out information, the stress health monitoring module is used for analyzing the stress distribution condition of the dust remover according to the signals of all the sensors, and the upper computer can display the stress change condition of the dust remover in real time. The stress and deformation states of the component can be monitored in real time, so that safe operation of the structure is guaranteed.

Description

Technical Field

[0001] The invention relates to the field of dust collector structure monitoring, and in particular to a dust collector structure monitoring system and method. Background Art

[0002] Due to its own characteristics, the traditional dust collector has a structural form different from the general steel structure. The removed dust is stored in the ash hopper and then transported by the ash conveying system. Therefore, the ash level in the ash hopper changes in real time. The temperature also changes with the different ash accumulation times. Therefore, the load on the steel structure changes in real time. Currently, only the ash hopper level can indirectly judge the structural load caused by the ash level, and there is no effective detection method to detect the impact of this change on the steel structure. Moreover, the dust collector shell is a large-span spatial structure, and its main stress source is negative pressure. Usually, the outer shell has an insulation layer, and the deformation of the shell cannot be seen through daily inspections.

[0003] In order to monitor and diagnose the health status of the dust collector structure, discover structural damage in time, predict possible disasters, monitor ash dropping and determine ash blockage, and perform interlocking operations on the dust collector to improve the safety of dust collector operation, solve the problem that manual inspection is impossible, and improve the structural monitoring efficiency of the dust collector; Based on the above problems, we therefore propose a dust collector structure monitoring system and method. Summary of the invention

[0004] Therefore, the technical problem to be solved by the present invention is that in the prior art, it is impossible to monitor the structural integrity of the dust collector in real time and ensure the safety of the equipment during operation.

[0005] The above technical problems are solved by the following technical solutions: The present invention proposes a dust collector structure monitoring system, which includes a detection module arranged on the dust collector, a data processing module connected to the detection module, a host computer and a stress health monitoring module connected to the data processing module, and a prompt module connected to the host computer; and, the detection module transmits the signal to the data processing module, the data processing module analyzes and processes the data, and displays the result on the host computer; when an abnormal signal is detected, the data processing module sends a message, the stress health monitoring module is used to analyze the stress distribution of the dust collector according to the signals of each sensor, and the host computer can display the stress changes of the dust collector in real time.

[0006] In a preferred embodiment of the dust collector structure monitoring system of the present invention: the detection module includes a grating sensor arranged on the bottom beam of the dust collector, which is used to collect the strain value of the bottom beam of the dust collector, and the detection module also includes an ultrasonic detector installed on one side of the weld position between the ash hopper wall panel and the bottom beam, which is used to collect whether the weld between the ash hopper and the bottom beam of the dust collector is abnormal.

[0007] In a preferred embodiment of the dust collector structure monitoring system of the present invention: the detection module also includes a leak detector installed on the ash hopper wall panel for detecting whether the ash hopper is leaking ash; and a PT resistor installed on the ash hopper wall panel for collecting the temperature of the dust collector ash hopper.

[0008] In a preferred embodiment of the dust collector structure monitoring system of the present invention: the detection module also includes a sinusoidal strain gauge for collecting deformation of the dust collector column and shell; and a level sensor for collecting the height of ash accumulation in the dust collector hopper.

[0009] In a preferred embodiment of the dust collector structure monitoring system of the present invention: the detection module also includes a straight pipe section temperature sensor arranged in the ash dropping straight pipe of the dust collector ash hopper; and an ash hopper outlet temperature sensor and a silo pump outlet temperature sensor arranged on the dust collector ash hopper; the dust collector ash hopper is also provided with a high and low level meter.

[0010] In a preferred embodiment of the dust collector structure monitoring system of the present invention: the data processing module also includes a dust collector structure calculation submodule and a centralized data processing and analysis submodule; and, wherein, the dust collector structure calculation submodule is used to establish a calculation model based on the data actually transmitted by each detection device in the detection module, and output the structural stress of the dust collector body in real time, and compare it with the predetermined limit stress, and output various real-time parameters of the dust collector structure safety.

[0011] The above technical problem is solved by the following technical solution: The present invention proposes a dust collector structure monitoring method, which also includes establishing a threshold-based early warning system, dividing the dust collector steel structure support into three levels: center column, side center column and corner column, and independently evaluating the health status of each level.

[0012] In a preferred implementation of the dust collector structure monitoring method described in the present invention: a direct analysis method is used to extract and analyze large deformation characteristics of the bracket, and based on the direct analysis results of the steel structure bracket, monitoring points of the dust collector steel structure bracket are selected, and a method for solving the early warning value is constructed.

[0013] In a preferred embodiment of the dust collector structure monitoring method of the present invention: based on the analysis results, the health of components at different levels is solved, and the coordinated change characteristics between the material level and the stress are analyzed in combination with the material level data and the stress data, and the health judgment logic is established;

[0014] Warning value solution indicators:

[0015]

[0016] is the warning value of the (i, j)th support column, λ is the characteristic equation d(K U +λK G )=0, Q is the load value of the structure, N ij is the converted axial force value on the (i, j)th support column, A ij is the cross-sectional area of ​​the (i, j)th support column, M ij is the converted bending moment value on the (i, j)th support column, y is the distance from the farthest point of the support column section to the neutral axis, and I is the moment of inertia of the (i, j)th support column;

[0017] A health warning model is built through intelligent algorithms to calculate the health of components at different levels, thereby performing real-time diagnosis of the health of the steel structure support of the dust collector;

[0018] Indicators for determining the health of components at different levels of steel structure supports:

[0019]

[0020] I ij is the health of the (i, j)th support column, Δσ is the stress change measured on site, ΔQ is the silo load change measured on site, To solve the warning value of the (i, j)th support column.

[0021] In a preferred implementation of the dust collector structure monitoring method of the present invention: based on the calculated data, the health of three types of columns, namely the center column, the side center column and the corner column, is evaluated respectively, potential problems are identified, and early warnings are issued in time to ensure the overall safety and reliability of the structure.

[0022] The beneficial effects of the present invention are as follows: by proposing a dust collector structure monitoring system, the sensor equipment collects the structural status of the dust collector in real time, thereby realizing real-time structural monitoring of the dust collector; by analyzing and processing the structural parameters through the data processing module, the structural problems of the dust collector are discovered in time, thereby improving the accuracy of safety warnings; the safety warning information is displayed through the host computer unit, and an alarm signal is sent to remind the staff to take timely measures to reduce the risk of safety accidents; by real-time monitoring of the stress and deformation state of the components, the structural change characteristics are calculated, the dust collector structure and the overall safe use status are evaluated, and timely warnings are issued. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments of the present invention are briefly introduced below. Obviously, the drawings described below only relate to some embodiments of the present invention, but are not intended to limit the present invention. Among them:

[0024] Figure 1Shows a schematic diagram of the dust collector detection position connection;

[0025] Figure 2 A schematic diagram of dust collector hopper dust falling monitoring is shown;

[0026] Figure 3 A block diagram of a dust collector structure monitoring system is shown;

[0027] Figure 4 The schematic diagram of the plane distribution of monitoring point selection is shown;

[0028] Figure 5 Shows Figure 4 Schematic diagram of the vertical distribution of the measurement points selected in columns A and F;

[0029] Figure 6 Shows Figure 4 Schematic diagram of the vertical distribution of the measurement points selected in columns B and E;

[0030] Figure 7 Shows Figure 4 Schematic diagram of the vertical distribution of the measurement points selected in columns C and D;

[0031] Figure 8 A schematic diagram of the buckling mode of the dust collector frame is shown;

[0032] Fig. 9 A deformation cloud diagram of the dust collector frame is shown;

[0033] Fig.10 The stress cloud diagram of the dust collector frame is shown;

[0034] Fig.11 A schematic diagram of the load-stress curve is shown. DETAILED DESCRIPTION

[0035] In order to enable those skilled in the art to better understand the present invention, the present invention is further described in detail below in conjunction with specific implementation methods and drawings.

[0036] The terms used in the present invention are those general terms currently widely used in the art in consideration of the functions of the present invention, but these terms may vary according to the intention of a person of ordinary skill in the art, precedents, or new technologies in the art. In addition, specific terms may be selected by the applicant, and in this case, their detailed meanings will be described in the detailed description of the present invention. Therefore, the terms used in the specification should not be understood as simple names, but rather as a general description based on the meaning of the terms and the present invention.

[0037] Reference Figure 1 to Figure 3This embodiment provides a dust collector structure monitoring system, including a detection module 1 arranged on the dust collector, a data processing module 2 connected to the detection module 1, a host computer 3 and a stress health monitoring module 4 connected to the data processing module 2, and a prompt module 5 connected to the host computer 3; and, the detection module 1 transmits a signal to the data processing module 2, the data processing module 2 analyzes and processes the data, and displays the result on the host computer 3; when an abnormal signal is detected, the data processing module 2 sends a message, the stress health monitoring module 4 is used to analyze the stress distribution of the dust collector according to the signals of each sensor, and the host computer 3 can display the stress change of the dust collector in real time.

[0038] Each monitoring device transmits a signal to the data processing module 2 , which analyzes and processes the data and displays the result on a data storage and display unit on the host computer 3 .

[0039] The data processing module 2 is used to receive signals from various instruments and perform data analysis and processing. When an abnormal signal is detected, the module issues a prompt.

[0040] The prompt module 5 is connected to the data processing module 2 and is used to issue an audio and visual prompt when receiving a prompt instruction from the data processing module.

[0041] The host computer is connected to the data processing module 2 and is used to store monitoring data and display the status of each parameter in real time.

[0042] The stress health monitoring module 4 may adopt stress health monitoring software.

[0043] As an optional embodiment, the detection module 1 includes a grating sensor 11 arranged on the bottom beam of the dust collector, which is used to collect the strain value of the bottom beam of the dust collector. The detection module 1 also includes an ultrasonic detector 12 installed on one side of the weld between the ash hopper wall panel and the bottom beam, which is used to collect whether the weld between the ash hopper and the bottom beam of the dust collector is abnormal.

[0044] The grating sensor 11 is installed on the bottom beam of the dust collector by gluing, and is mainly used to detect the displacement of the ash hopper, steel frame and key components, and transmit the signal to the data processing module 2.

[0045] The ultrasonic detector 12 is used to detect the condition of the steel structure of the dust collector, including weld cracking, steel plate corrosion, etc., and transmit the signal to the data processing module 2.

[0046] As an optional embodiment, the detection module 1 further includes a leak detector 13 installed on the ash hopper wall plate for detecting whether the ash hopper is leaking ash; and a PT resistor 14 installed on the ash hopper wall plate for collecting the temperature of the dust collector ash hopper.

[0047] The leak detector 13 is used to detect leakage in the sealing part of the dust collector and transmit the leakage signal to the data processing module 2.

[0048] The PT resistor 14 is used to detect the internal temperature and transmit the temperature signal to the data processing module so as to monitor the structural stress caused by the temperature change.

[0049] As an optional embodiment, the detection module 1 further includes a sinusoidal strain gauge 15 for collecting deformation of the dust collector column and the shell; and a level sensor 16 for collecting the height of the ash accumulation level in the dust collector hopper.

[0050] The sinusoidal strain gauge 15 is installed at the key stress-bearing position of the dust collector to detect the strain of the structure and transmit the strain signal to the data processing module 2.

[0051] The material level sensor 16 is installed on the ash hopper to monitor the change of the ash level in the ash hopper and transmit the strain signal to the data processing module 2.

[0052] As an optional embodiment, the detection module 1 also includes a straight pipe section temperature sensor 17 arranged in the ash dropping straight pipe of the dust collector ash hopper; as well as an ash hopper outlet temperature sensor 18 and a silo pump outlet temperature sensor 19 arranged on the dust collector ash hopper; and a high and low level meter 110 is also arranged on the dust collector ash hopper.

[0053] like Figure 2 As shown, temperature sensors are installed on the straight pipe sections of the silo pump outlet, ash hopper outlet and silo pump inlet of the ash conveying system to monitor the temperature changes of the silo pump inlet and outlet to determine whether the ash hopper is dropping ash normally and whether the ash conveying system is conveying ash normally; when the ash hopper is not dropping ash smoothly and the pipe is blocked, the temperature along the ash falling process will drop. When the temperature is lower than the set temperature, the monitoring system will immediately control the alarm to sound an alarm, indicating that the pipe is blocked. The operating personnel can adjust the ash conveying parameters in time to avoid excessive dust accumulation in the ash hopper in advance.

[0054] When the main program module detects the alarm information and starts the alarm, it first detects the alarm source and sends the alarm name and status to the upper computer, and then automatically takes different measures according to the alarm level and point, such as opening the specified valve, starting the vibration of the vibrator, and running the emergency ash conveying system, and starts the buzzer device at the same time. It can further be linked with the dust collector operation system to adjust the dust collector operation parameters to avoid excessive local dust accumulation and ensure the safe operation of the dust collector.

[0055] As an optional embodiment, the data processing module 2 also includes a dust collector structure calculation submodule and a centralized data processing and analysis submodule; and, wherein, the dust collector structure calculation submodule is used to establish a calculation model based on the data actually transmitted by each detection device in the detection module 1, and output the structural stress of the dust collector body in real time, and compare it with the predetermined limit stress, and output various real-time parameters of the dust collector structure safety.

[0056] Strain sensors are arranged at key positions of the dust collector steel bracket, steel bracket support, ash hopper and other main components to convert the strain into component stress and transmit it to the computer processing system. After calculation, storage and comparison with the pre-set initial stress, it is displayed to the staff. If it exceeds the preset value, an alarm will be triggered.

[0057] Reference Figures 1 to 11 ,This embodiment provides a dust collector structure monitoring method, including establishing a threshold-based early warning system, by dividing the dust collector steel structure support into three levels of center column, side center column and corner column, and independently evaluating the health status of each level.

[0058] First of all, it is necessary to fully consider the stability and bearing capacity of the steel structure support under the influence of large deformation, and under the working conditions of reasonably considering the adverse effects of component stability (① bending, shear and axial deformation of the component, and all deformations that affect the structural displacement; ② second-order effect (P-δ effect); ③ geometric defects; ④ component stiffness degradation caused by inelastic deformation), the direct analysis method is used to extract and analyze the large deformation characteristics of the support, and the deformation degree and deformation trend of the component are truly described, which not only ensures the rationality of the selection of monitoring points, but also ensures the accuracy of solving the early warning value. Based on the direct analysis results of the steel structure support, the monitoring points of the dust collector steel structure support are selected, and a solution method for the early warning value is constructed.

[0059] As an optional embodiment, a direct analysis method is used to extract and analyze the large deformation characteristics of the bracket. According to the direct analysis results of the steel structure bracket, the monitoring points of the dust collector steel structure bracket are selected, and a solution method for the early warning value is constructed; Figure 4 The following are the results of monitoring point selection.

[0060] As an optional embodiment, based on the analysis results, the health of components at different levels is solved, and the coordinated change characteristics between the material level and the stress are analyzed by combining the material level data and the stress data, and the functional relationship between them is quantitatively described to establish the health judgment logic;

[0061] Warning value solution indicators:

[0062]

[0063] is the warning value of the (i, j)th support column, λ is the characteristic equation d(K U +λK G )=0, Q is the load value of the structure, N ij is the converted axial force value on the (i, j)th support column, A ij is the cross-sectional area of ​​the (i, j)th support column, M ij is the converted bending moment value on the (i, j)th support column, y is the distance from the farthest point of the support column section to the neutral axis, and I is the moment of inertia of the (i, j)th support column; K U is the element stiffness matrix after considering stiffness reduction, K G is the geometric stiffness matrix.

[0064] A health warning model is built through intelligent algorithms to calculate the health of components at different levels, thereby performing real-time diagnosis of the health of the steel structure support of the dust collector;

[0065] Indicators for determining the health of components at different levels of steel structure supports:

[0066]

[0067] I ij is the health of the (i, j)th support column, Δσ is the stress change measured on site, ΔQ is the silo load change measured on site, To solve the warning value of the (i, j)th support column.

[0068] As an optional embodiment, the health of three types of columns, namely, center columns, side center columns and corner columns, is evaluated separately based on the calculated data, potential problems are identified, and early warnings are issued in a timely manner to ensure the overall safety and reliability of the structure.

[0069] In structural health monitoring, the stress characteristics and bearing capacity of the center column, side center column and corner column are different. Among them, the center column has the largest bearing capacity and is mainly responsible for bearing vertical loads. Although the side center column has a strong bearing capacity, it is more affected by the external environment. The corner column has a relatively small bearing capacity and faces complex loads from two directions. By evaluating the health of these three types of columns separately, potential problems can be identified more accurately, early warnings can be issued in time, and the overall safety and reliability of the structure can be ensured. This hierarchical analysis method not only improves the accuracy of monitoring, but also provides a basis for the implementation of effective maintenance and reinforcement measures.

[0070] According to the geometric dimensions and operating conditions of the dust collector system, the numerical simulation model of the dust collector frame was established using the ABAQUS software simulation platform. The ABAQUS direct analysis method was used to extract and analyze the large deformation characteristics of the bracket to truly reflect the deformation trend of the structure and components and the early warning characteristic values ​​when the structure is unstable. Figure 8 to Figure 11 The figure shows the data simulation implementation diagram.

[0071] In this study, the constitutive model of steel at room temperature adopts a double-broken line model, and the elastic modulus of steel is E = 2.06×10 5 N / mm 2 , Poisson's ratio is 0.3, the plastic strain corresponding to the ultimate strength is calculated according to the plastic strain data in the steel material property test, the nominal strain is converted into the real strain input, and the steel yield strength f y =305N / mm 2 , ultimate strength f u =420N / mm 2 .

[0072] The buckling analysis of the dust collector frame is carried out according to the direct analysis method. The first four buckling modes of the frame are as follows: Figure 8 As shown, according to the first four buckling modes, it can be seen that the buckling of the dust removal frame mainly occurs in the corner columns, side columns and middle columns, and the buckling load solved according to the eigenvalue is 248KN for a single ash hopper.

[0073] According to the buckling load calculated by the direct analysis method, the corresponding load is applied to the structure and the structural response is calculated to obtain the deformation cloud diagram of the structure under the buckling load. Fig. 9 As shown, the stress cloud diagram is Fig.10 As shown in the figure; according to the structural response under the buckling load, the load stress curves of frame columns at different positions can be extracted to provide a basis for setting the early warning value.

[0074] There are two cross-sectional sizes for the dust collector frame columns. The cross-sectional size of the frame center column is HW400×400×13×21mm, and the cross-sectional size of the other frame columns is HW300×300×10×15mm. Due to the different stress states of frame columns with different cross-sections and different positions, it is necessary to set the stress change rate warning value respectively. The load-stress curves of the dust collector frame center column, side center column and corner column are obtained based on the buckling simulation results of the dust collector frame, such as Fig.11 As shown, the stress change rate warning value of each type of frame column can be analyzed; the dust collector structure monitoring method is applicable to various dust collector steel structure supports.

[0075] Finally, it should be pointed out that the methods and devices described in detail above are only embodiments, and those skilled in the art can modify these embodiments in different ways without departing from the scope of the present invention.

Claims

1. A dust collector structure monitoring system, characterized in that: A detection module (1) arranged on the dust collector, a data processing module (2) connected to the detection module (1), a host computer (3) and a stress health monitoring module (4) connected to the data processing module (2), and a prompt module (5) connected to the host computer (3); and, The detection module (1) transmits the signal to the data processing module (2), and the data processing module (2) analyzes and processes the data and displays the result on the host computer (3); when an abnormal signal is detected, the data processing module (2) sends a message, and the stress health monitoring module (4) is used to analyze the stress distribution of the dust collector according to the signals of each sensor, and the host computer (3) can display the stress change of the dust collector in real time.

2. The dust collector structure monitoring system according to claim 1, characterized in that: The detection module (1) comprises a grating sensor (11) arranged on the bottom beam of the dust collector, and is used to collect the strain value of the bottom beam of the dust collector. The detection module (1) also comprises an ultrasonic detector (12) installed on one side of the weld position between the ash hopper wall plate and the bottom beam, and is used to collect whether the weld between the ash hopper and the bottom beam of the dust collector is abnormal.

3. The dust collector structure monitoring system according to claim 2, characterized in that: The detection module (1) also includes a leak detector (13) installed on the ash hopper wall plate for detecting whether the ash hopper is leaking ash; and a PT resistor (14) installed on the ash hopper wall plate for collecting the temperature of the dust collector ash hopper.

4. The dust collector structure monitoring system according to claim 3, characterized in that: The detection module (1) also includes a sinusoidal strain gauge (15) for collecting deformation of the dust collector column and shell; and a material level sensor (16) for collecting the height of the dust accumulation level in the dust collector hopper.

5. The dust collector structure monitoring system according to claim 4, characterized in that: The detection module (1) further comprises a straight pipe section temperature sensor (17) arranged in the ash dropping straight pipe of the dust collector ash hopper; and an ash hopper outlet temperature sensor (18) and a silo pump outlet temperature sensor (19) arranged on the dust collector ash hopper. The dust collector hopper is also provided with a high and low material level meter (110).

6. The dust collector structure monitoring system according to claim 5, characterized in that: The data processing module (2) also includes a dust collector structure calculation submodule and a centralized data processing and analysis submodule; as well as, The dust collector structure calculation submodule is used to establish a calculation model based on the data actually transmitted by each detection device in the detection module (1), and output the structural stress of the dust collector body in real time, and compare it with the predetermined limit stress, and output various real-time parameters of the dust collector structure safety.

7. A dust collector structure monitoring method, characterized in that: The dust collector structure monitoring system according to any one of claims 1 to 6 further comprises: A threshold-based early warning system is established, and the health status of each level is independently evaluated by dividing the dust collector steel structure support into three levels: center column, side center column and corner column.

8. The dust collector structure monitoring system according to claim 7, characterized in that: The direct analysis method is used to extract and analyze the large deformation characteristics of the support. According to the direct analysis results of the steel structure support, the monitoring points of the dust collector steel structure support are selected, and a solution method for the early warning value is constructed.

9. The dust collector structure monitoring system according to claim 8, characterized in that: Based on the analysis results, the health of components at different levels is solved, and the coordinated change characteristics between material level and stress are analyzed by combining material level data and stress data, and the health judgment logic is established; Warning value solution indicators: is the warning value of the (i, j)th support column, λ is the characteristic equation d(K U +λK G )=0, Q is the load value of the structure, N ij is the converted axial force value on the (i, j)th support column, A ij is the cross-sectional area of ​​the (i, j)th support column, M ij is the converted bending moment value on the (i, j)th support column, y is the distance from the farthest point of the support column section to the neutral axis, and I is the moment of inertia of the (i, j)th support column; A health warning model is built through intelligent algorithms to calculate the health of components at different levels, thereby performing real-time diagnosis of the health of the steel structure support of the dust collector; Indicators for determining the health of components at different levels of steel structure supports: I ij is the health of the (i, j)th support column, Δσ is the stress change measured on site, ΔQ is the silo load change measured on site, To solve the warning value of the (i, j)th support column.

10. The dust collector structure monitoring system according to claim 9, characterized in that: Based on the calculated data, the health of the three types of columns, namely the center column, side center column and corner column, is evaluated separately to identify potential problems and issue early warnings in a timely manner to ensure the overall safety and reliability of the structure.

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