A corrosion resistance data monitoring system and method for thermal sprayed aluminum anti-corrosion layer

Abstract

The present invention discloses a corrosion-resistant data monitoring system and method for thermally sprayed aluminum anti-corrosion coatings, relating to the field of experimental data management. The system includes a test scenario construction module, a data acquisition module, a constant temperature control module, and a data processing module. By separately setting up a test group and a reference group and simultaneously deploying multiple sensor integration units, the system ensures the scientific nature of experimental control and the spatial comprehensiveness of data acquisition. Experimental parameters are dynamically adjusted based on the polarization characteristics and electrical response intervals of the metal substrate. A built-in local processor performs real-time comparisons, and a central processor further performs data processing and dynamic temperature regulation, achieving rational resource allocation and significantly enhancing the reliability of experimental data.

Description

Technical Field

[0001] The present invention relates to the field of test data management, and in particular to a corrosion resistance data monitoring system and method for a thermal sprayed aluminum anti-corrosion layer. Background Art

[0002] Thermal Sprayed Aluminum (TSA), a highly effective corrosion protection method for metal surfaces, has been widely used on metal substrates exposed to long-term, highly corrosive environments, such as marine engineering, storage tank cladding, steel structures, bridges, and chemical equipment. This technology utilizes a thermal spraying process to melt aluminum wire and spray it onto the workpiece surface at high speed, forming a dense aluminum coating that effectively isolates the workpiece from oxygen and electrolytes while providing excellent sacrificial anodic protection, significantly extending the service life of the base metal.

[0003] However, despite the obvious advantages of thermal sprayed aluminum anti-corrosion coatings in terms of protective performance, their corrosion behavior during long-term service is still affected by many factors, such as changes in ambient temperature and humidity, intrusion of electrochemical corrosive media, micro-crack propagation, and decreased coating porosity and adhesion. Therefore, in actual engineering applications, it is difficult to fully grasp the dynamic corrosion state and degradation process of the anti-corrosion coating under actual working conditions by relying solely on thermal spray construction quality control. Therefore, it is necessary to finely manage and process the corrosion resistance data of the thermal sprayed aluminum anti-corrosion coating during the experimental testing phase to achieve accurate quantification of the anti-corrosion coating status.

[0004] Existing technology, such as the invention patent with announcement number CN117078003B, is a risk assessment method for corrosion of static equipment, comprising the following steps: setting multiple monitoring points on the static equipment, obtaining parameters of each monitoring point on the static equipment, the parameters including equipment service time a, equipment design wall thickness td, corrosion margin C, corrosion rate r, and wall thickness monitoring data t at the monitoring point; obtaining the corrosion degree A of each monitoring point through the above parameters, taking the maximum value maxA of the corrosion degree A of each monitoring point as the corrosion severity index of this static equipment, and obtaining the corrosion risk level Z of this static equipment according to the corrosion severity index.

[0005] The existing technology, such as the invention patent with announcement number: CN112085320B, is a method for grading and evaluating the corrosion resistance of grounding materials, which includes the following steps: S1. Constructing a corrosion resistance grading evaluation table: selecting a sample of a certain material as a comparison sample, and selecting typical grounding materials on the market, such as stainless steel, copper, and carbon steel, as scoring benchmark samples, and using the scoring reference of 100 points for stainless steel, 80 points for copper, and 60 points for carbon steel to determine the numerical range of the relative corrosion rate α with scores of 100 points, 80 points, 60 points, 40 points, and 20 points; S2. Determination of the relative corrosion rate α of the target sample; S3. Scoring of the target sample: Finding the corresponding score in the corrosion resistance grading evaluation table according to the relative corrosion rate α of the target sample, and recording it as the target sample score.

[0006] Based on the above-mentioned existing technical solutions, it can be seen that the existing technology often relies on static or indirect sampling of physical data to infer the degree of corrosion, and it is difficult to dynamically perceive the corrosion process. In addition, in the corrosion resistance test of materials, the test data is greatly affected by the test environment. The existing technology directly collects test data after testing in actual applications, which may make the test data invalid. Summary of the Invention

[0007] In view of the shortcomings of the existing technology, the present invention provides a corrosion resistance data monitoring system and method for a thermal sprayed aluminum anti-corrosion layer. To achieve the above objectives, the present invention is implemented through the following technical solutions: A corrosion resistance data monitoring system for a thermal sprayed aluminum anti-corrosion layer, comprising:

[0008] The test scenario building module is used to record the panel with the thermal sprayed aluminum anti-corrosion layer as the test panel and the panel without the thermal sprayed aluminum anti-corrosion layer as the reference panel, and deploy multiple sensor integration units on the test panel and the reference panel.

[0009] The data acquisition module is used to perform corrosion tests on the test panel and the reference panel at the same time. After the electrochemical parameter acquisition configuration is performed on each sensor integrated unit, the surface corrosion electrochemical parameters of the test panel and the reference panel are monitored.

[0010] The constant temperature control module is used to collect temperature data in real time and compare it with the set target temperature, and perform control and adjustment based on the temperature difference.

[0011] The data processing module is used to perform preliminary processing and judgment on the real-time electrochemical parameters of the test panel through the built-in local processor of each sensor integrated unit. If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing.

[0012] As a preferred technical solution, multiple sensor integration units are deployed. The specific process is as follows:

[0013] The metal base material number of the panel is obtained, and mapped and matched with the material number-electrode spacing mapping set pre-stored in the database to obtain the electrode spacing corresponding to the metal base material of the panel.

[0014] Based on the electrode spacing, a reference calibration electrode is deployed at the main measuring electrode of each sensor integrated unit. The reference calibration electrode is used to monitor and calibrate the accuracy of each sensor integrated unit during the automatic monitoring and calibration period.

[0015] The sensor integration units are deployed on the test panel and the reference panel according to the preset deployment density.

[0016] As a preferred technical solution, each sensor integrated unit is configured to collect electrochemical parameters. The specific process is as follows:

[0017] The electrochemical parameter acquisition configuration specifically includes: setting the disturbance voltage amplitude and frequency scanning strategy.

[0018] Set the disturbance voltage amplitude. The specific process includes:

[0019] The polarization resistance value and the material linear response range of the metal base material of the panel are obtained, and the polarization resistance value of the metal base material of the panel is input into the standard perturbation mapping function of the polarization resistance value-disturbance amplitude influence factor. The perturbation amplitude influence factor of the panel is obtained by mapping and matching.

[0020] The preset linear response interval parameter model is called to obtain the upper limit of the maximum linear disturbance voltage amplitude.

[0021] The basic disturbance amplitude is extracted from the database, and the basic disturbance amplitude is corrected based on the disturbance amplitude influencing factor of the panel to obtain the theoretical disturbance voltage amplitude of the panel. The theoretical disturbance voltage amplitude of the panel is compared with the upper limit of the maximum linear disturbance voltage amplitude. The disturbance voltage amplitude is obtained based on the comparison result and applied to the electrochemical parameter acquisition.

[0022] Frequency sweep strategy, including the start frequency, end frequency, and sweep step value of the test panel and reference panel.

[0023] Starting frequency: By obtaining the total resistance, parasitic inductance and parasitic capacitance of the sensor integrated unit, the high-frequency limit frequency is calculated based on the total resistance and parasitic inductance. At the same time, the parasitic capacitance value is input into the parasitic capacitance-interference frequency mapping set to obtain the capacitance interference frequency. Finally, the smaller value of the two is selected as the starting frequency of the test panel and the reference panel.

[0024] The termination frequency, for the reference panel, is obtained by calculating the corresponding electrochemical time constant based on the polarization resistance value of the metal base material of the panel, and this frequency is used as the termination frequency of the reference panel.

[0025] For the test panel, before configuring the frequency scanning strategy, a rapid electrochemical impedance scan is performed on other panels with a thermally sprayed aluminum anti-corrosion layer to obtain the impedance drop inflection point. The frequency corresponding to this inflection point is extracted and defined as the diffusion-controlled frequency. At the same time, the background noise during the rapid electrochemical impedance scan process is collected and put into the noise-termination frequency influence factor mapping centralized matching to obtain the termination frequency influence factor. Based on the termination frequency influence factor, the diffusion-controlled frequency is corrected to determine the termination frequency of the test panel.

[0026] Scanning step value: For a reference panel, the preset scanning step value of the reference panel is extracted from the database to configure each sensor integrated unit of the reference panel.

[0027] For the test panel, the frequency scanning range value of the test panel is obtained based on the starting frequency and the ending frequency of the test panel, and the frequency scanning range value of the test panel is ratio-processed with the frequency scanning range value of the reference panel to obtain the frequency scanning range deviation ratio of the test panel. The preset scanning step value is proportionally corrected based on the frequency scanning range deviation ratio. After the correction, each sensor integrated unit of the test panel is configured. The frequency scanning range deviation ratio is the ratio of the frequency range value of the test panel to the frequency range value of the reference panel, and is used to linearly correct the preset scanning step value to ensure the consistency of the sampling density.

[0028] As a preferred technical solution, monitor the electrochemical corrosion parameters of the test panel and reference panel surface, including:

[0029] The corrosion electrochemical parameters of each sensor integrated unit of the test panel and the reference panel include static electrochemical parameters, impedance spectrum electrochemical parameters and polarization electrochemical parameters.

[0030] When entering the calibration cycle of each sensor integrated unit, the actual acquisition circuit is disconnected and switched to the reference calibration circuit. The reference electrode is read and compared with the initial calibration value to obtain the electrode offset value of each sensor integrated unit. If the electrode offset value of a sensor integrated unit is within the preset tolerance range, the current calibration result is recorded and the sensor is restored to the normal acquisition state. At the same time, the parameter correction mechanism is started and the electrode offset value is put into the mapping set of electrode offset value-deviation correction coefficient to obtain the deviation correction coefficient of the sensor integrated unit to correct the corrosion electrochemical parameters of each sensor integrated unit. At the same time, the calibration interval period length of the sensor integrated unit is adjusted. If the electrode offset value of a sensor integrated unit is not within the preset tolerance range, an alarm is issued.

[0031] As a preferred technical solution, real-time temperature data is collected and compared with the set target temperature, and control and adjustment are performed according to the temperature difference, specifically including:

[0032] Temperature data is collected in real time and compared with the set target temperature to obtain the temperature difference value. At the same time, the instantaneous temperature change rate is obtained by subtracting it from the temperature value at the previous moment. If the instantaneous temperature change rate is continuously lower than the instantaneous temperature change rate threshold and the current temperature difference value is less than or equal to the temperature difference tolerance threshold, the temperature is judged to be in equilibrium and switched to the insulation mode.

[0033] If the instantaneous temperature change rate is higher than the instantaneous temperature change rate threshold or the temperature difference is greater than the temperature difference tolerance threshold, the system switches to the temperature control mode and calls the preset proportional-integral-differential controller to adjust the temperature to the target temperature.

[0034] As a preferred technical solution, each sensor integrated unit has a built-in local processor to perform preliminary processing and judgment on the real-time electrochemical parameters of the test panel, specifically including:

[0035] A set of coarse judgment thresholds for static electrochemical parameters, impedance spectrum electrochemical parameters, and polarization electrochemical parameters are extracted from the database. The electrochemical parameters of each sensor integrated unit of the test panel are compared one by one with the coarse judgment threshold set. The electrochemical parameters exceeding the coarse judgment threshold are counted and recorded as corrosion performance parameters. Each corrosion performance parameter is subtracted from the corresponding coarse judgment threshold to obtain each corrosion performance difference. Each corrosion performance difference is then input into the corresponding standard perturbation mapping function of corrosion performance difference-corrosion projection unit factor, and the corrosion projection unit factor of each corrosion performance parameter is obtained by mapping and matching.

[0036] The corrosion performance difference of each sensor integrated unit and its corresponding corrosion projection unit factor are corrected and coupled to obtain the test panel corrosion phenomenon judgment value of each sensor integrated unit. If the test panel corrosion phenomenon judgment value of a sensor integrated unit exceeds the preset corrosion phenomenon judgment threshold, it is judged that the sensor integrated unit has corrosion phenomenon at the location where the test panel is deployed, and the sensor integrated unit is recorded as a corrosion sensor integrated unit.

[0037] As a preferred technical solution, if corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing, including:

[0038] After the central processor receives the electrochemical parameters of each corrosion sensor integrated unit, it calls up the electrochemical parameters of each sensor integrated unit of the reference panel, inputs the input into the built-in algorithm model of the central processor, generates and outputs the electrochemical parameter change curve set of each sensor integrated unit of the reference panel, extracts the electrochemical parameter theoretical standard change curve set from the database, compares the electrochemical parameter change curve set of each sensor integrated unit of the reference panel with the electrochemical parameter theoretical standard change curve set one by one, and obtains the electrochemical parameter deviation value of each sensor integrated unit after processing by the built-in curve algorithm of the central processor. After averaging, the overall deviation evaluation value of the electrochemical parameters of the reference panel is obtained. If the overall deviation evaluation value of the electrochemical parameters of the reference panel is less than the preset overall deviation evaluation threshold of the electrochemical parameters, the test is determined to be a valid test, and the electrochemical parameters of each corrosion sensor integrated unit are valid data. The correction processing is based on the overall deviation evaluation value of the electrochemical parameters of the reference panel and then fine processing is performed.

[0039] If the overall deviation evaluation value of the electrochemical parameters of the reference panel is greater than or equal to the preset electrochemical parameter overall deviation evaluation threshold, the test is judged to be an invalid test and an early warning is sent to the test management terminal.

[0040] As a preferred technical solution, the overall deviation of the electrochemical parameters of the reference panel from the evaluation value is corrected. The specific processing conditions are as follows:

[0041] The overall deviation evaluation value of the electrochemical parameters of the reference panel is extracted, and the difference is made with the preset overall deviation evaluation threshold of the electrochemical parameters to obtain the overall deviation evaluation difference of the electrochemical parameters of the reference panel. The overall deviation evaluation difference of the electrochemical parameters of the reference panel is put into the mapping set of the overall deviation evaluation difference of the electrochemical parameters-data correction coefficient to obtain the data correction coefficient of the electrochemical parameters of each corrosion sensor integrated unit, and the electrochemical parameters of each corrosion sensor integrated unit are corrected and then refined.

[0042] As the preferred technical solution, fine processing is carried out, and the specific processing process includes:

[0043] After the central processor obtains the corrected electrochemical parameters of each corrosion sensor integrated unit, it inputs the parameters into the built-in algorithm model of the central processor to generate a set of test corrosion curves of each corrosion sensor integrated unit.

[0044] A set of theoretical corrosion curves of the test panel is extracted from the database and compared with the set of experimental corrosion curves of each corrosion sensor integrated unit. After processing by the built-in curve algorithm of the central processor, the overall experimental corrosion curve similarity of each corrosion sensor integrated unit is obtained. If the overall experimental corrosion curve similarity of a corrosion sensor integrated unit is greater than or equal to the curve similarity threshold, it is determined that the corrosion phenomenon of the corrosion sensor integrated unit is normal.

[0045] If the similarity of the overall test corrosion curve of a corrosion sensor integrated unit is less than the curve similarity threshold, it is determined that the corrosion phenomenon of the corrosion sensor integrated unit is abnormal. The slope of the test corrosion curve set of the corrosion sensor integrated unit at each time sampling point is calculated and compared with the slope of the theoretical corrosion curve set at each time sampling point. The time sampling point where the slope difference is greater than the difference threshold is recorded as an abnormal inflection point. The electrochemical parameters at each abnormal inflection point are counted, packaged into an abnormal inflection point data packet, and sent to the test management terminal.

[0046] A method for a corrosion resistance data monitoring system for a thermal sprayed aluminum anti-corrosion layer, comprising:

[0047] The panel with the thermal sprayed aluminum anti-corrosion layer is recorded as the test panel, and the panel without the thermal sprayed aluminum anti-corrosion layer is recorded as the reference panel. Multiple sensor integration units are deployed on the test panel and the reference panel.

[0048] The corrosion test is performed on the test panel and the reference panel at the same time. After the electrochemical parameter acquisition configuration is performed on each sensor integrated unit, the surface corrosion electrochemical parameters of the test panel and the reference panel are monitored.

[0049] Collect temperature data in real time and compare it with the set target temperature, and make control adjustments based on the temperature difference.

[0050] The real-time electrochemical parameters of the test panel are preliminarily processed and judged through the built-in local processor of each sensor integrated unit. If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing.

[0051] Compared with the prior art, the embodiments of the present invention have at least the following beneficial effects:

[0052] (1) The present invention provides a corrosion resistance data monitoring system for thermally sprayed aluminum anti-corrosion coatings. By using panels with thermally sprayed aluminum anti-corrosion coatings and untreated panels as test and reference groups, and deploying multiple sensor integration units, the scientific nature of experimental control and the spatial comprehensiveness of data acquisition are ensured. Experimental parameters are dynamically adjusted based on the polarization characteristics and electrical response range of the metal substrate to ensure that data is sampled within the valid range, thereby improving data quality.

[0053] (2) This invention introduces a multi-level intelligent judgment and feedback mechanism in electrochemical data acquisition and processing. At the sensor integration unit level, the system's embedded local processor performs real-time comparisons of static electrochemical parameters, impedance parameters, and polarization parameters, and completes preliminary identification and quantitative inference of corrosion phenomena based on the difference in corrosion performance parameters and mapping functions. This significantly improves the real-time performance of front-end judgments and reduces the data transmission load. The central processor further performs reference panel deviation assessment and corrosion data correction. Through theoretical curve comparison and dynamic threshold adjustment, abnormal electrochemical parameters are accurately identified and corrected, ensuring the scientificity and effectiveness of the final corrosion assessment results.

[0054] (3) The present invention realizes dynamic perception and precise regulation of temperature fluctuations during the experiment through a constant temperature control module, effectively eliminating the interference of external temperature disturbances on the corrosion test results. In addition, the system constructs a joint judgment mechanism of curve similarity and slope difference, which improves the accuracy of identifying abnormal corrosion behavior and significantly enhances the data reliability of the test.

[0055] Of course, any product implementing the present invention does not necessarily need to achieve all of the above advantages at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 Schematic diagram of the system module of the present invention.

[0057] Figure 2 Schematic diagram of the method of the present invention. DETAILED DESCRIPTION

[0058] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0059] In the description of the present invention, it should be understood that the terms "opening", "upper", "lower", "thickness", "top", "middle", "length", "inside", "around" and the like indicating orientation or positional relationship are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0060] See also Figure 1 As shown, an embodiment of the present invention provides a corrosion resistance data monitoring system for a thermal sprayed aluminum anti-corrosion layer, specifically comprising:

[0061] The test scenario building module is used to record the panel with the thermal sprayed aluminum anti-corrosion layer as the test panel and the panel without the thermal sprayed aluminum anti-corrosion layer as the reference panel, and deploy multiple sensor integration units on the test panel and the reference panel.

[0062] Deploy multiple sensor integration units. The specific process is as follows:

[0063] The metal base material number of the panel is obtained, and mapped and matched with the material number-electrode spacing mapping set pre-stored in the database to obtain the electrode spacing corresponding to the metal base material of the panel.

[0064] It should be noted that different metal substrate materials have different electrical conductivities, electrode reactions, and polarization behaviors. For example, the electrode spacing obtained by matching aluminum alloy with material number LY12 is 8 mm, and the electrode spacing obtained by matching stainless steel with material number 304SS is 3 mm. Because aluminum alloy has high conductivity, a slightly larger spacing can still obtain a stable impedance signal. However, stainless steel has a passivation film and high polarization resistance, so the electrode spacing needs to be reduced to enhance the induced current and response sensitivity.

[0065] Based on the electrode spacing, a reference calibration electrode is deployed at the main measuring electrode of each sensor integrated unit. The reference calibration electrode is used to monitor and calibrate the accuracy of each sensor integrated unit during the automatic monitoring and calibration period.

[0066] Electrode spacing refers to the spatial distance between the main measuring electrode and the reference calibration electrode, which affects the sensitivity, resolution and current path of electrochemical testing.

[0067] The main measuring electrode refers to the electrode that performs the main impedance test and corrosion current acquisition.

[0068] The reference calibration electrode refers to an electrode specifically used for reference potential detection or precision calibration, and works together with the main electrode to perform voltage reference comparison during operation.

[0069] The sensor integration units are deployed on the test panel and the reference panel according to the preset deployment density.

[0070] The data acquisition module is used to perform corrosion tests on the test panel and the reference panel at the same time. After the electrochemical parameter acquisition configuration is performed on each sensor integrated unit, the surface corrosion electrochemical parameters of the test panel and the reference panel are monitored.

[0071] Each sensor integrated unit performs electrochemical parameter acquisition configuration. The specific process is as follows:

[0072] The electrochemical parameter acquisition configuration specifically includes: setting the disturbance voltage amplitude and frequency scanning strategy.

[0073] Set the disturbance voltage amplitude. The specific process includes:

[0074] The polarization resistance value and material linear response range of the metal base material pre-stored on the panel are obtained from the database. The polarization resistance value reflects the degree of impedance of the material surface to current changes. The material linear response range defines the range in which the material still maintains ohmic behavior under small disturbance voltage.

[0075] The polarization resistance value of the metal base material of the panel is input into the standard perturbation mapping function of polarization resistance value-disturbance amplitude influence factor, and the perturbation amplitude influence factor of the panel is obtained by mapping and matching. The perturbation amplitude influence factor is a dimensionless coefficient determined based on the polarization resistance value in the standard perturbation mapping function, which is used to characterize the degree of influence of polarization resistance on the electrochemical response sensitivity of the panel.

[0076] The material linear response interval is used to define the controllable range of the disturbance voltage amplitude. The preset linear response interval parameter model is called to obtain the upper limit of the maximum linear disturbance voltage amplitude in the test scenario. The upper limit of the maximum linear disturbance voltage amplitude serves as a hard constraint condition for the disturbance voltage setting range.

[0077] The basic disturbance amplitude is extracted from the database, and the basic disturbance amplitude is corrected based on the disturbance amplitude influencing factor of the panel. The correction process is to multiply the disturbance amplitude influencing factor of the panel with the basic disturbance amplitude to obtain the theoretical disturbance voltage amplitude of the panel. The theoretical disturbance voltage amplitude of the panel is compared with the upper limit of the maximum linear disturbance voltage amplitude. If the theoretical disturbance voltage amplitude of the panel is less than the upper limit of the maximum linear disturbance voltage amplitude, the theoretical disturbance voltage amplitude of the panel is used as the disturbance voltage amplitude and applied to the electrochemical parameter collection. If the theoretical disturbance voltage amplitude of the panel is greater than or equal to the upper limit of the maximum linear disturbance voltage amplitude, the upper limit of the maximum linear disturbance voltage amplitude is used as the disturbance voltage amplitude and applied to the electrochemical parameter collection.

[0078] Frequency sweep strategy, including the start frequency, end frequency, and sweep step value of the test panel and reference panel.

[0079] Starting frequency, by obtaining the total resistance value, parasitic inductance value and parasitic capacitance value of the sensor integrated unit, the high-frequency limit frequency is calculated based on the total resistance value and parasitic inductance value. The specific formula is: ,in, is the high frequency limit frequency, is the total resistance value, The parasitic inductance value is input into the parasitic capacitance-interference frequency mapping set to obtain the capacitance interference frequency. Finally, the smaller value between the high-frequency limit frequency and the capacitance interference frequency is selected as the starting frequency of the test panel and the reference panel.

[0080] It should be noted that the total resistance value, parasitic inductance value and parasitic capacitance value of the sensor integrated unit are the three elements of the impedance of the sensor integrated unit. The total resistance value represents the total series resistance of the sensor integrated unit in the electrical signal path, including the ohmic resistance of the electrode body material, the contact path resistance and the electrolyte resistance, which is used to determine the signal transmission capability in the high-frequency region. The parasitic inductance value is the non-ideal inductance effect formed by the leads, welding paths and packaging layout of the sensor integrated unit, which generates inductive reactance at high frequencies and affects the test signal. The parasitic capacitance value refers to the non-ideal distributed capacitance formed between two conductors, which manifests as a decrease in capacitive reactance at high frequencies, forming a signal bypass and reducing the effective signal amplitude.

[0081] For the reference panel, the end frequency is calculated based on the polarization resistance of the metal substrate material of the panel and the corresponding electrochemical time constant to obtain the frequency. This frequency is used as the end frequency of the reference panel. The specific process includes: ,in, is the electrochemical time constant, is the polarization resistance value of the metal base material, For a known electrochemical double layer capacitance, the calculation process of its termination frequency is: .

[0082] For the test panel, before configuring the frequency scanning strategy, a fast electrochemical impedance scan is performed on other panels with a thermal sprayed aluminum anti-corrosion layer to obtain the impedance drop inflection point, and the frequency corresponding to the inflection point is extracted and defined as the diffusion control frequency. At the same time, the background noise in the fast electrochemical impedance scan process is collected and put into the noise-termination frequency influence factor mapping centralized matching to obtain the termination frequency influence factor. The greater the noise, the lower the reliability of the high-frequency signal and the smaller the termination frequency influence factor. Based on the termination frequency influence factor, the diffusion control frequency is corrected to determine the termination frequency of the test panel. It should be noted that the termination frequency influence factor is a dimensionless real number coefficient used to quantitatively describe the termination frequency. The degree of influence of background noise on the reliability of high-frequency signals is described, and its value range is limited to (0,1). When the background noise is small, the signal is clear, and the termination frequency influence factor is close to 1, indicating that the high-frequency signal is highly reliable and the correction amplitude of the diffusion control frequency is small. When the background noise is large, the signal is severely interfered with, and the termination frequency influence factor is close to 0, indicating that the reliability of the high-frequency signal is low and the termination frequency needs to be significantly reduced to avoid the influence of noise. The specific process of correcting the diffusion control frequency by the termination frequency influence factor is: multiplying the termination frequency influence factor by the diffusion control frequency to obtain the corrected diffusion control frequency, and using the corrected diffusion control frequency as the termination frequency of the test panel.

[0083] The impedance drop inflection point marks the transition from the charge transfer controlled phase to the diffusion controlled phase. The charge transfer controlled phase is the phase in the electrochemical reaction dominated by the process of charge transfer from the electrode surface to the electrolyte, typically manifested as the mid- to high-frequency bands of the impedance spectrum. In this phase, the impedance reflects the electron transfer rate. The diffusion controlled phase refers to the electrochemical reaction in which, after the frequency drops to a certain level, the electrochemical process becomes diffusion-limited. This means that the diffusion of reactants, such as metal ions, from the solution to the electrode surface becomes the rate-limiting step, typically manifested as the low-frequency region of the impedance spectrum.

[0084] The diffusion-controlled frequency refers to the boundary frequency point between the charge transfer-controlled stage and the diffusion-controlled stage in the electrochemical impedance spectroscopy.

[0085] Scanning step value: For a reference panel, the preset scanning step value of the reference panel is extracted from the database to configure each sensor integrated unit of the reference panel.

[0086] For the test panel, the frequency scan range value of the test panel is obtained based on the starting frequency and ending frequency of the test panel. The frequency scan range deviation ratio of the test panel is obtained by ratio processing with the frequency scan range value of the reference panel. The preset scan step value is proportionally corrected based on the frequency scan range deviation ratio. After the correction, each sensor integrated unit of the test panel is configured. The frequency scan range deviation ratio is the ratio of the frequency range value of the test panel to the frequency range value of the reference panel. It is used to linearly correct the preset scan step value to ensure sampling density consistency. The specific calculation process includes:

[0087]

[0088] in, is the scan step value of the test panel, is the preset scan step value of the reference panel, is the starting frequency of the test panel, is the termination frequency of the test panel, is the starting frequency of the reference panel, is the end frequency of the reference panel.

[0089] Collect electrochemical corrosion parameters of the test panel and reference panel surface, including:

[0090] The corrosion electrochemical parameters of each sensor integrated unit of the test panel and the reference panel include static electrochemical parameters, impedance spectrum electrochemical parameters and polarization electrochemical parameters. The static electrochemical parameters include open circuit potential and stabilization time. The impedance spectrum electrochemical parameters include the phase angle of the electrochemical impedance spectrum, the characteristic radius of the Nyquist diagram, the platform interval impedance and the inflection point frequency. The polarization electrochemical parameters include the corrosion current density, corrosion potential and polarization resistance of the polarization curve.

[0091] Open circuit potential refers to the electrode potential naturally reached by the electrode without any external current or voltage, reflecting the natural electrochemical state of the material.

[0092] The stabilization time refers to the time required to reach the stable value of the open circuit potential, which reflects the speed at which the system reaches a stable state.

[0093] Phase angle refers to the phase difference between current and voltage at different frequencies and is used to describe the electrochemical behavior of the electrode interface.

[0094] The Nyquist plot characteristic radius refers to the radius of the semicircle in the Nyquist plot, which is usually related to the charge transfer impedance and reflects the corrosion rate.

[0095] The platform impedance refers to the stable impedance value range in the impedance spectrum, which reflects the electrochemical properties of the material surface.

[0096] The inflection point frequency refers to the frequency point at which the shape of the curve in the impedance spectrum changes, usually corresponding to different electrochemical process transitions.

[0097] Corrosion current density indicates the size of the corrosion current per unit area and directly reflects the corrosion rate.

[0098] Corrosion potential refers to the potential point at which the electrode reaches the corrosion reaction, reflecting the corrosion activity.

[0099] Polarization resistance refers to the ability of the electrode surface to hinder corrosion reactions. The larger the polarization resistance, the lower the corrosion rate is usually.

[0100] When entering the calibration cycle of each sensor integrated unit, the actual acquisition circuit is disconnected and switched to the reference calibration circuit. The reference electrode is read and compared with the initial calibration value to obtain the electrode offset value of each sensor integrated unit. If the electrode offset value of a certain sensor integrated unit is within the preset tolerance range, the current calibration result is recorded, the sensor is restored to the normal acquisition state, and the parameter correction mechanism is started at the same time. The electrode offset value is input into the mapping set of electrode offset value-deviation correction coefficient to obtain the deviation correction coefficient of the sensor integrated unit and correct the corrosion electrochemical parameters of the sensor integrated unit. The correction process is to multiply the deviation correction coefficient of the sensor integrated unit with the corrosion electrochemical parameters of the sensor integrated unit, including multiplying it with the static electrochemical parameters to obtain the corrected static electrochemical parameters, multiplying it with the impedance spectroscopy electrochemical parameters to obtain the corrected impedance spectroscopy electrochemical parameters, and multiplying it with the polarization electrochemical parameters to obtain the corrected polarization electrochemical parameters. At the same time, the calibration interval period length of the sensor integrated unit is adjusted. If the electrode offset value of a certain sensor integrated unit is not within the preset tolerance range, an alarm is issued.

[0101] The deviation correction coefficient is used to quantify the influence of electrode offset value on corrosion electrochemical parameters, and its value range is (0, +∞).

[0102] Adjust the calibration interval period length. The specific process is as follows:

[0103] The electrode offset value of the sensor integrated unit is put into the mapping set of electrode offset value-calibration interval period length extension value, and the calibration interval period length extension process is performed after the calibration interval period length extension value of the sensor integrated unit is obtained by mapping matching.

[0104] The constant temperature control module is used to collect temperature data in real time and compare it with the set target temperature, and perform control and adjustment based on the temperature difference.

[0105] Collect temperature data in real time and compare it with the set target temperature, and make adjustments based on the temperature difference, including:

[0106] The temperature sensing module in each sensor integrated unit collects temperature data in real time and compares it with the set target temperature to obtain the temperature difference value. At the same time, it subtracts the temperature value from the previous moment to obtain the instantaneous temperature change rate. If the instantaneous temperature change rate is continuously lower than the instantaneous temperature change rate threshold and the current temperature difference value is less than or equal to the temperature difference tolerance threshold, it is judged that the temperature is in equilibrium and switches to the insulation mode.

[0107] If the instantaneous temperature change rate is higher than the instantaneous temperature change rate threshold or the temperature difference is greater than the temperature difference tolerance threshold, the system switches to temperature control mode and calls the preset proportional-integral-differential controller to adjust the temperature to the target temperature. The specific process is as follows:

[0108] The temperature difference is input as an error term into a proportional-integral-derivative controller, and the proportional-integral-derivative output control signal controls the power of the constant temperature control module.

[0109] The data processing module is used to perform preliminary processing and judgment on the real-time electrochemical parameters of the test panel through the built-in local processor of each sensor integrated unit. If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing.

[0110] Each sensor integration unit has a built-in local processor to perform preliminary processing and judgment on the real-time electrochemical parameters of the test panel, including:

[0111] A set of coarse judgment threshold values of electrochemical parameters is extracted from the database, and the electrochemical parameters of each sensor integrated unit of the test panel are compared one by one with the coarse judgment threshold value set of electrochemical parameters. The electrochemical parameters that deviate from the coarse judgment threshold value are counted and recorded as corrosion performance parameters. It should be noted that in the embodiment of the present invention, for the parameters of stabilization time, platform interval impedance and corrosion current density, if they are greater than the corresponding coarse judgment threshold value, they are judged to deviate from the coarse judgment threshold value; for the parameters of Nyquist diagram characteristic radius, polarization resistance and corrosion potential, if they are less than the corresponding coarse judgment threshold value, they are judged to deviate from the coarse judgment threshold value; for the parameters of inflection point frequency, phase angle and open circuit potential, if the difference with the corresponding coarse judgment threshold value exceeds the corresponding allowable deviation value, it is judged to deviate from the coarse judgment threshold value.

[0112] The corrosion performance parameters are subtracted from the corresponding coarse judgment threshold to obtain the corrosion performance differences. The corrosion performance differences are then input into the corresponding standard perturbation mapping function of the corrosion performance difference-corrosion projection unit factor. The corrosion projection unit factor of each corrosion performance parameter is obtained by mapping and matching. The corrosion projection unit factor is a dimensionless coefficient determined in the standard perturbation mapping function based on each corrosion performance difference, and is used to characterize the degree of influence of the corrosion performance parameter on the determination of whether corrosion occurs.

[0113] The corrosion performance difference of each sensor integrated unit is corrected and coupled with its corresponding corrosion projection unit factor to obtain the corrosion phenomenon judgment value of the test panel of each sensor integrated unit, which specifically includes:

[0114] ;

[0115] in, is the corrosion phenomenon judgment value of the test panel of the zth sensor integrated unit, is the corrosion performance difference of the i-th sensor integrated unit, is the corrosion projection unit factor of the ith corrosion performance difference of the zth sensor integrated unit, z is the sensor integrated unit number, , is the total number of sensor integrated units, i is the corrosion performance difference number, , is the total number of corrosion performance differences.

[0116] If the test panel corrosion phenomenon judgment value of a certain sensor integrated unit exceeds the preset corrosion phenomenon judgment threshold, it is judged that the sensor integrated unit has corrosion phenomenon at the position where the test panel is deployed, and the sensor integrated unit is recorded as a corrosion sensor integrated unit.

[0117] If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing, including:

[0118] After receiving the electrochemical parameters of each corrosion sensor integrated unit, the central processor retrieves the electrochemical parameters of each sensor integrated unit of the reference panel, inputs the parameters into the built-in algorithm model of the central processor, and generates and outputs a set of electrochemical parameter change curves of each sensor integrated unit of the reference panel. In an embodiment of the present invention, the built-in algorithm model of the central processor is a Savitzky-Golay filter. The set of electrochemical parameter change curves of each sensor integrated unit of the reference panel includes an open circuit potential change curve, a corrosion current density change curve, and an electrochemical impedance spectroscopy change curve. A set of theoretical standard change curves of electrochemical parameters is extracted from a database, including a theoretical standard change curve of open circuit potential, a theoretical standard change curve of corrosion current density, and a theoretical standard change curve of electrochemical impedance spectroscopy. A number of sampling points are selected, and based on each sampling point, the set of electrochemical parameter change curves of each sensor integrated unit of the reference panel is compared one by one with the set of theoretical standard change curves of electrochemical parameters. After processing by the built-in curve algorithm of the central processor, the electrochemical parameter deviation value of each sensor integrated unit is obtained, and after averaging processing, the overall deviation evaluation value of the electrochemical parameters of the reference panel is obtained.

[0119] Obtain the electrochemical parameter deviation value of each sensor integrated unit, specifically including:

[0120] ;

[0121] ;

[0122] ;

[0123] ;

[0124] in, is the electrochemical parameter deviation value of the zth sensor integrated unit of the reference panel, is the mean square error of the open circuit potential of the zth sensor integrated unit of the reference panel, The zth sensor integrated unit of the reference panel is The measured open circuit potential value at the time point, The zth sensor integrated unit of the reference panel is The theoretical standard open circuit potential value at the time point, is the mean square error of the corrosion current density of the zth sensor integrated unit of the reference panel, The zth sensor integrated unit of the reference panel is The measured corrosion current density at the time point, The zth sensor integrated unit of the reference panel is Theoretical standard corrosion current density at a time point, is the maximum relative deviation rate of the impedance spectrum of the zth sensing integrated unit of the reference panel, is the measured impedance value of the zth sensing integrated unit of the reference panel, is the theoretical standard impedance value, z is the sensor integrated unit number, , is the total number of sensor integrated units, is the sampling point number, , is the total number of sampling points, is the open circuit potential mean square error weighted by the unity factor, is the weighted unity factor of the mean square error of corrosion current density, The unit factor weighting for the maximum relative deviation rate of the impedance spectrum.

[0125] It should be noted that the weighted unit factor of the mean square error of the open circuit potential, the weighted unit factor of the mean square error of the corrosion current density, and the weighted unit factor of the maximum relative deviation rate of the impedance spectrum are as follows: the weighted unit factor of the mean square error of the open circuit potential is the standardized influence intensity coefficient corresponding to the mean square error between the open circuit potential and its theoretical standard variation curve, and is used to characterize the relative influence weight of the open circuit potential deviation in the calculation of electrochemical parameter deviation values. The weighted unit factor of the mean square error of the corrosion current density is a dimensionless coefficient determined by projecting the mean square error between the corrosion current density variation trend and its theoretical standard curve into the corrosion rate mapping function, and is used to characterize the relative influence weight of the corrosion current density deviation in the calculation of electrochemical parameter deviation values. The weighted unit factor of the maximum relative deviation rate of the impedance spectrum is the response sensitivity coefficient projected based on the maximum relative deviation rate between the measured electrochemical impedance spectrum and the standard spectrum line in each frequency band, and is used to characterize the relative influence weight of the impedance spectrum deviation in the calculation of electrochemical parameter deviation values.

[0126] The overall deviation evaluation value of the electrochemical parameters of the reference panel is obtained, including:

[0127] ;

[0128] in, is the overall deviation evaluation value of the electrochemical parameters of the reference panel, is the electrochemical parameter deviation value of the zth sensor integrated unit of the reference panel, z is the sensor integrated unit number, , is the total number of sensor integrated units.

[0129] If the overall deviation evaluation value of the electrochemical parameters of the reference panel is less than the preset overall deviation evaluation threshold of the electrochemical parameters, the test is judged to be a valid test, and the electrochemical parameters of each corrosion sensor integrated unit are valid data. The correction processing is based on the overall deviation evaluation value of the electrochemical parameters of the reference panel and then fine processing is performed.

[0130] If the overall deviation evaluation value of the electrochemical parameters of the reference panel is greater than or equal to the preset electrochemical parameter overall deviation evaluation threshold, the test is judged to be an invalid test and an early warning is sent to the test management terminal.

[0131] Correction of overall deviation of electrochemical parameters from the evaluation value based on the reference panel. The specific processing conditions are as follows:

[0132] The overall deviation evaluation value of the electrochemical parameters of the reference panel is extracted, and the difference is made with the preset overall deviation evaluation threshold of the electrochemical parameters to obtain the overall deviation evaluation difference of the electrochemical parameters of the reference panel. The overall deviation evaluation difference of the electrochemical parameters of the reference panel is put into the mapping set of the overall deviation evaluation difference of the electrochemical parameters-data correction coefficient to obtain the data correction coefficient of the electrochemical parameters of each corrosion sensor integrated unit, and the electrochemical parameters of each corrosion sensor integrated unit are corrected and then refined. The correction process includes multiplying the data correction coefficient with the electrochemical parameter.

[0133] Carry out fine processing, the specific processing process includes:

[0134] After the central processor obtains the corrected electrochemical parameters of each corrosion sensor integrated unit, it inputs the parameters into the built-in algorithm model of the central processor to generate a set of test corrosion curves of each corrosion sensor integrated unit, including the open circuit potential test corrosion change curve, the corrosion current density test corrosion change curve and the electrochemical impedance spectroscopy test corrosion change curve.

[0135] It should be noted that in the test corrosion curve set of each corrosion sensor integrated unit, the horizontal axis of the curve is the time in the corrosion test. The test corrosion curve set of each corrosion sensor integrated unit is used to visualize the changes in various parameters of the test panel during the corrosion test as the corrosion test progresses.

[0136] A set of theoretical corrosion curves of the test panel is extracted from the database, including the open circuit potential theoretical corrosion change curve, the corrosion current density theoretical corrosion change curve and the electrochemical impedance spectroscopy theoretical corrosion change curve, and compared with the experimental corrosion curve set of each corrosion sensor integrated unit. After processing by the built-in curve algorithm of the central processor, the overall experimental corrosion curve similarity of each corrosion sensor integrated unit is obtained. In the embodiment of the present invention, the built-in curve algorithm of the central processor is a dynamic time algorithm and a Pearson correlation coefficient algorithm. If the overall experimental corrosion curve similarity of a corrosion sensor integrated unit is greater than or equal to the curve similarity threshold, it is determined that the corrosion phenomenon of the corrosion sensor integrated unit is normal.

[0137] If the similarity of the overall test corrosion curve of a corrosion sensor integrated unit is less than the curve similarity threshold, it is determined that the corrosion phenomenon of the corrosion sensor integrated unit is abnormal, and the slope of the test corrosion curve set of the corrosion sensor integrated unit at each time sampling point is calculated. The calculation process includes taking the points on each test corrosion curve at each time sampling point to obtain the tangent of each point, extending each tangent to obtain the intersection with the coordinate axis, and obtaining the slope of each tangent based on the intersection coordinates and the binary linear equation. The slope is compared with the slope of the theoretical corrosion curve set at each time sampling point and the difference is obtained. The time sampling point where the slope difference is greater than the difference threshold is recorded as an abnormal inflection point, and the electrochemical parameters of the corrosion sensor integrated unit at each abnormal inflection point are counted, and the data are packaged into an abnormal inflection point data packet and sent to the test management terminal.

[0138] like Figure 2 In this embodiment, the present invention provides a method for monitoring corrosion resistance data of a thermally sprayed aluminum anti-corrosion layer, comprising:

[0139] The panel with the thermal sprayed aluminum anti-corrosion layer is recorded as the test panel, and the panel without the thermal sprayed aluminum anti-corrosion layer is recorded as the reference panel. Multiple sensor integration units are deployed on the test panel and the reference panel.

[0140] The corrosion test is performed on the test panel and the reference panel at the same time. After the electrochemical parameter acquisition configuration is performed on each sensor integrated unit, the surface corrosion electrochemical parameters of the test panel and the reference panel are monitored.

[0141] Collect temperature data in real time and compare it with the set target temperature, and make control adjustments based on the temperature difference.

[0142] The real-time electrochemical parameters of the test panel are preliminarily processed and judged through the built-in local processor of each sensor integrated unit. If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing.

[0143] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0144] The preferred embodiments of the present invention disclosed above are only used to help illustrate the present invention. The preferred embodiments do not describe all details in detail, nor do they limit the invention to specific implementation methods. Obviously, many modifications and changes can be made based on the contents of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can better understand and utilize the present invention. As long as they do not deviate from the structure of the present invention or exceed the scope defined by the present invention, they should fall within the scope of protection of the present invention.

Claims

1. A corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer, characterized in that: include: A test scenario building module is used to record a panel with a thermally sprayed aluminum anti-corrosion layer as a test panel and a panel without a thermally sprayed aluminum anti-corrosion layer as a reference panel, and to deploy multiple sensor integration units on the test panel and the reference panel; The data acquisition module is used to perform corrosion tests on the test panel and the reference panel simultaneously. After each sensor integrated unit is configured to collect electrochemical parameters, it monitors the electrochemical parameters of corrosion on the surface of the test panel and the reference panel. Constant temperature control module, used to collect temperature data in real time and compare it with the set target temperature, and perform control and adjustment according to the temperature difference; The data processing module is used to perform preliminary processing and judgment on the real-time electrochemical parameters of the test panel through the built-in local processor of each sensor integrated unit. If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing; The electrochemical parameter acquisition configuration specifically includes: setting the disturbance voltage amplitude and frequency scanning strategy; The specific process of setting the disturbance voltage amplitude includes: Obtain the polarization resistance value and material linear response range of the panel's metal base material, apply the polarization resistance value of the panel's metal base material to a standard perturbation mapping function of polarization resistance value-perturbation amplitude influence factor, and obtain the panel's perturbation amplitude influence factor through mapping and matching. Calling the preset linear response interval parameter model to obtain the upper limit of the maximum linear disturbance voltage amplitude; The basic disturbance amplitude is extracted from the database, and the basic disturbance amplitude is corrected based on the disturbance amplitude influencing factor of the panel to obtain the theoretical disturbance voltage amplitude of the panel. The theoretical disturbance voltage amplitude of the panel is compared with the upper limit of the maximum linear disturbance voltage amplitude. The disturbance voltage amplitude is obtained based on the comparison result and applied to the electrochemical parameter acquisition.

2. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 1, characterized in that: The specific process of deploying multiple sensor integration units is as follows: Obtain the metal substrate material number of the panel, and perform mapping matching with the material number-electrode spacing mapping set pre-stored in the database to obtain the electrode spacing corresponding to the metal substrate material of the panel; Deploy reference calibration electrodes at the main measuring electrodes of each sensor integrated unit based on the electrode spacing, wherein the reference calibration electrodes are used to monitor and calibrate the accuracy of each sensor integrated unit during the automatic monitoring and calibration period; The sensor integration units are deployed on the test panel and the reference panel according to the preset deployment density.

3. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 1, characterized in that: Each sensor integrated unit performs electrochemical parameter acquisition configuration, and the specific process is as follows: The frequency scanning strategy specifically includes the starting frequency, ending frequency and scanning step value of the test panel and the reference panel; The starting frequency is obtained by obtaining the total resistance, parasitic inductance and parasitic capacitance of the sensor integrated unit, calculating the high-frequency limit frequency based on the total resistance and parasitic inductance, and inputting the parasitic capacitance into the parasitic capacitance-interference frequency mapping set to obtain the capacitance interference frequency. Finally, the smaller value of the two is selected as the starting frequency of the test panel and the reference panel; The end frequency, for the reference panel, is obtained by calculating the corresponding electrochemical time constant based on the polarization resistance value of the metal base material of the panel, and this frequency is used as the end frequency of the reference panel; Before configuring the frequency sweep strategy for the test panel, a rapid electrochemical impedance spectroscopy (EIS) scan was performed on other panels with a thermally sprayed aluminum anti-corrosion coating to obtain the impedance drop inflection point. The frequency corresponding to this inflection point was extracted and defined as the diffusion-controlled frequency. Simultaneously, background noise from the rapid EIS scan was collected and applied to a noise-to-stop frequency influencing factor mapping to obtain the stop frequency influencing factor. Based on this stop frequency influencing factor, the diffusion-controlled frequency was corrected to determine the stop frequency of the test panel. The scanning step value, for a reference panel, extracts the preset scanning step value of the reference panel from a database to configure each sensor integrated unit of the reference panel; For the test panel, the frequency scanning range value of the test panel is obtained based on the starting frequency and the ending frequency of the test panel, and the frequency scanning range value of the test panel is ratio-processed with the frequency scanning range value of the reference panel to obtain the frequency scanning range deviation ratio of the test panel. The preset scanning step value is proportionally corrected based on the frequency scanning range deviation ratio. After the correction, each sensor integrated unit of the test panel is configured. The frequency scanning range deviation ratio is the ratio of the frequency range value of the test panel to the frequency range value of the reference panel, and is used to linearly correct the preset scanning step value to ensure the consistency of the sampling density.

4. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 1, characterized in that: The monitoring of the electrochemical corrosion parameters of the test panel and the reference panel specifically includes: The corrosion electrochemical parameters of each sensor integrated unit of the test panel and the reference panel include static electrochemical parameters, impedance spectroscopy electrochemical parameters and polarization electrochemical parameters; When entering the calibration cycle of each sensor integrated unit, the actual acquisition circuit is disconnected and switched to the reference calibration circuit. The reference electrode is read and compared with the initial calibration value to obtain the electrode offset value of each sensor integrated unit. If the electrode offset value of a sensor integrated unit is within the preset tolerance range, the current calibration result is recorded and the sensor is restored to the normal acquisition state. At the same time, the parameter correction mechanism is started and the electrode offset value is put into the mapping set of electrode offset value-deviation correction coefficient to obtain the deviation correction coefficient of the sensor integrated unit to correct the corrosion electrochemical parameters of each sensor integrated unit. At the same time, the calibration interval period length of the sensor integrated unit is adjusted. If the electrode offset value of a sensor integrated unit is not within the preset tolerance range, an alarm is issued.

5. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 1, characterized in that: The real-time temperature data is collected and compared with the set target temperature, and control and adjustment are performed according to the temperature difference, specifically including: The temperature data is collected in real time and compared with the set target temperature to obtain the temperature difference value. At the same time, the temperature difference is subtracted from the temperature value at the previous moment to obtain the instantaneous temperature change rate. If the instantaneous temperature change rate is continuously lower than the instantaneous temperature change rate threshold and the current temperature difference value is less than or equal to the temperature difference tolerance threshold, the temperature is judged to be in equilibrium and the mode is switched to the insulation mode. If the instantaneous temperature change rate is higher than the instantaneous temperature change rate threshold or the temperature difference is greater than the temperature difference tolerance threshold, the system switches to the temperature control mode and calls the preset proportional-integral-differential controller to adjust the temperature to the target temperature.

6. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 1, characterized in that: Each sensor integrated unit has a built-in local processor that performs preliminary processing and judgment on the real-time electrochemical parameters of the test panel, specifically including: Extracting a set of coarse judgment thresholds for static electrochemical parameters, impedance spectroscopy electrochemical parameters, and polarization electrochemical parameters from a database, comparing the electrochemical parameters of each sensor integrated unit of the test panel with the coarse judgment threshold set one by one, counting the electrochemical parameters exceeding the coarse judgment threshold and recording them as corrosion performance parameters, subtracting each corrosion performance parameter from the corresponding coarse judgment threshold to obtain each corrosion performance difference, applying each corrosion performance difference to a corresponding standard perturbation mapping function of corrosion performance difference-corrosion projection unit factor, and mapping and matching to obtain the corrosion projection unit factor of each corrosion performance parameter; The corrosion performance difference of each sensor integrated unit and its corresponding corrosion projection unit factor are corrected and coupled to obtain the test panel corrosion phenomenon judgment value of each sensor integrated unit. If the test panel corrosion phenomenon judgment value of a sensor integrated unit exceeds the preset corrosion phenomenon judgment threshold, it is judged that the sensor integrated unit has corrosion phenomenon at the location where the test panel is deployed, and the sensor integrated unit is recorded as a corrosion sensor integrated unit.

7. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 1, characterized in that: If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing, specifically including: After the central processor receives the electrochemical parameters of each corrosion sensor integrated unit, it retrieves the electrochemical parameters of each sensor integrated unit of the reference panel, inputs the input into the built-in algorithm model of the central processor, generates and outputs a set of electrochemical parameter change curves of each sensor integrated unit of the reference panel, extracts a set of theoretical standard change curves of electrochemical parameters from the database, compares the set of electrochemical parameter change curves of each sensor integrated unit of the reference panel with the set of theoretical standard change curves of electrochemical parameters one by one, obtains the electrochemical parameter deviation value of each sensor integrated unit after processing by the built-in curve algorithm of the central processor, and obtains the overall deviation evaluation value of the electrochemical parameters of the reference panel after averaging. If the overall deviation evaluation value of the electrochemical parameters of the reference panel is less than the preset overall deviation evaluation threshold value of the electrochemical parameters, the test is determined to be a valid test, and the electrochemical parameters of each corrosion sensor integrated unit are valid data. The correction processing is performed based on the overall deviation evaluation value of the electrochemical parameters of the reference panel and then fine processing is performed; If the overall deviation evaluation value of the electrochemical parameters of the reference panel is greater than or equal to the preset overall deviation evaluation threshold of the electrochemical parameters, the test is judged to be an invalid test and an early warning is sent to the test management terminal.

8. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 7, characterized in that: The electrochemical parameters of the reference panel are corrected for the overall deviation from the evaluation value and then refined. The specific processing conditions are: The overall deviation evaluation value of the electrochemical parameters of the reference panel is extracted, and the difference is made with the preset overall deviation evaluation threshold of the electrochemical parameters to obtain the overall deviation evaluation difference of the electrochemical parameters of the reference panel. The overall deviation evaluation difference of the electrochemical parameters of the reference panel is put into the mapping set of the overall deviation evaluation difference of the electrochemical parameters-data correction coefficient to obtain the data correction coefficient of the electrochemical parameters of each corrosion sensor integrated unit, and the electrochemical parameters of each corrosion sensor integrated unit are corrected and then refined.

9. The corrosion resistance data monitoring system for thermal sprayed aluminum anti-corrosion layer according to claim 8, characterized in that: The fine processing includes the following steps: After the central processor obtains the corrected electrochemical parameters of each corrosion sensor integrated unit, it inputs them into the built-in algorithm model of the central processor to generate a set of test corrosion curves of each corrosion sensor integrated unit; A set of theoretical corrosion curves of the test panel is extracted from the database and compared with the set of experimental corrosion curves of each corrosion sensor integrated unit. After processing by the built-in curve algorithm of the central processor, the similarity of the overall experimental corrosion curves of each corrosion sensor integrated unit is obtained. If the similarity of the overall experimental corrosion curve of a corrosion sensor integrated unit is greater than or equal to the curve similarity threshold, the corrosion phenomenon of the corrosion sensor integrated unit is determined to be normal. If the similarity of the overall test corrosion curve of a corrosion sensor integrated unit is less than the curve similarity threshold, it is determined that the corrosion phenomenon of the corrosion sensor integrated unit is abnormal. The slope of the test corrosion curve set of the corrosion sensor integrated unit at each time sampling point is calculated and compared with the slope of the theoretical corrosion curve set at each time sampling point. The time sampling point where the slope difference is greater than the difference threshold is recorded as an abnormal inflection point. The electrochemical parameters at each abnormal inflection point are counted, packaged into an abnormal inflection point data packet, and sent to the test management terminal.

10. A method for a corrosion resistance data monitoring system for a thermal sprayed aluminum anti-corrosion layer according to any one of claims 1 to 9, characterized in that: The panel with the thermal sprayed aluminum anti-corrosion layer is recorded as the test panel, and the panel without the thermal sprayed aluminum anti-corrosion layer is recorded as the reference panel. Multiple sensor integration units are deployed on the test panel and the reference panel; The corrosion test is carried out on the test panel and the reference panel at the same time. After the electrochemical parameter acquisition configuration is performed on each sensor integrated unit, the corrosion electrochemical parameters of the test panel and the reference panel surface are monitored. Collect temperature data in real time and compare it with the set target temperature, and make control adjustments based on the temperature difference; The local processor built into each sensor integrated unit performs preliminary processing and judgment on the real-time electrochemical parameters of the test panel. If corrosion occurs, the electrochemical parameters are sent to the central processor for fine processing. The electrochemical parameter acquisition configuration specifically includes: setting the disturbance voltage amplitude and frequency scanning strategy; The specific process of setting the disturbance voltage amplitude includes: Obtain the polarization resistance value and material linear response range of the panel's metal base material, apply the polarization resistance value of the panel's metal base material to a standard perturbation mapping function of polarization resistance value-perturbation amplitude influence factor, and obtain the panel's perturbation amplitude influence factor through mapping and matching. Calling the preset linear response interval parameter model to obtain the upper limit of the maximum linear disturbance voltage amplitude; The basic disturbance amplitude is extracted from the database, and the basic disturbance amplitude is corrected based on the disturbance amplitude influencing factor of the panel to obtain the theoretical disturbance voltage amplitude of the panel. The theoretical disturbance voltage amplitude of the panel is compared with the upper limit of the maximum linear disturbance voltage amplitude. The disturbance voltage amplitude is obtained based on the comparison result and applied to the electrochemical parameter acquisition.

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