Assembly type enamel tank body state detection system

Abstract

The present application relates to the technical field of industrial container detection, and discloses an assembled enamel tank body state detection system, which comprises a three-dimensional sensor group arranged in a three-dimensional heterogeneous sensor network, is pasted on the surface of the enamel tank body, forms a biological neural network perception system, and an energy supply unit comprises a thermoelectric generator and a wireless charging embedded magnetic attraction power supply, which double ensures the power supply, and the inner wall corrosion diagnosis decodes the code of the inner wall corrosion position through the coded protective film, and the decoding result is positioned, so that the enamel tank body state is monitored all the time and in all domains, and the intelligent operation and maintenance level of industrial equipment is significantly improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial container detection, and discloses a fabricated enamel tank body state detection system. BACKGROUND

[0002] The prior art relies on a single sensor or manual visual detection, and it is difficult to realize complex defect recognition under multi-physical field coupling, especially the detection sensitivity of hidden defects such as micro-cracks and early corrosion is insufficient, and a three-dimensional perception network of the tank body state cannot be constructed, the corrosion diagnosis of the inner wall relies on offline sampling detection, and the dynamic positioning and non-contact real-time monitoring of the corrosion position cannot be realized, the sensor array layout is uneven due to the curved surface structure of the tank body, the signal attenuation in the edge area is obvious, the traditional rigid sensor is difficult to fit the curved surface, resulting in a detection blind area, and there is a lack of signal enhancement mechanism of bionics design, and the edge defects are prone to be missed. SUMMARY

[0003] This section is intended to summarize some aspects of the embodiments of the present application and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the abstract and title of the specification of the present application to avoid obscuring the purpose of this section, abstract and title, and such simplifications or omissions cannot be used to limit the scope of the present application.

[0004] To solve the above technical problems, the main purpose of the present application is to provide a fabricated enamel tank body state detection system, comprising:

[0005] The three-dimensional sensor group sets a three-dimensional heterogeneous sensor network, which is placed on the surface of the enamel tank body by sticking, forming a biological neural network perception system;

[0006] The energy supply unit includes thermoelectric power generation and wireless charging embedded magnetic power supply, which double ensures the power supply;

[0007] The inner wall corrosion diagnosis decodes the code of the inner wall corrosion place by coding the protective film, and locates the decoding result.

[0008] As a preferred scheme of the fabricated enamel tank body state detection system of the present application, wherein:

[0009] The three-dimensional heterogeneous sensor network includes a three-layer stacked structure, and the three-layer stacked structure includes a surface layer, an intermediate layer and a bottom layer;

[0010] The surface layer is a piezoelectric film array, which is densely packed on the surface of the enamel tank body in the form of a regular polygon;

[0011] The intermediate layer is a fiber grating, which is wound in a three-dimensional spiral, and the pitch of the three-dimensional spiral is determined by a regular polygon;

[0012] The bottom layer is composed of a miniaturized electromagnetic coil to form a differential eddy current probe.

[0013] As a preferred scheme of the assembled enamel tank state detection system of the application, wherein:

[0014] The biological neural network perception system comprises a synapse network, and the synapse network is constructed as a typed conductive network based on a flexible base;

[0015] The typed conductive network comprises a primary trunk and a secondary branch, the primary trunk is used for connecting a plurality of sensor clusters, and the secondary branch is used for connecting a single sensing unit;

[0016] The biological neural network working method comprises: a piezoelectric film array generates a time pulse sequence, a fiber grating outputs a frequency modulation signal, electromagnetic data is converted into pulse intensity, and an edge node performs pulse time sequence correlation analysis.

[0017] As a preferred scheme of the assembled enamel tank state detection system of the application, wherein:

[0018] The sensing network realizes multi-modal data fusion through a cooperative working mechanism of a three-layer stacked structure, and specifically comprises:

[0019] The surface piezoelectric film array detects dynamic stress waves on the surface of the enamel tank through a regular polygon dense packing configuration, and converts mechanical vibration into an electric pulse signal;

[0020] The middle layer fiber grating is based on three-dimensional spiral winding, a pitch of the three-dimensional spiral winding is determined by a regular polygon, and shear strain distribution of the tank is monitored in real time;

[0021] The bottom layer differential eddy current probe extracts electromagnetic characteristic parameters of a metal matrix inside the tank through a complementary layout of a miniaturized electromagnetic coil;

[0022] Three layers of data are fused through a space-time registration algorithm to generate a three-dimensional damage topology map, which is used for positioning a surface crack propagation path and an internal corrosion area.

[0023] As a preferred scheme of the assembled enamel tank state detection system of the application, wherein:

[0024] The primary trunk is composed of a cross-linking structure and extends along a curvature direction of the enamel tank to form a closed loop path;

[0025] The secondary branch diverges from the primary trunk at a certain angle, and a branch density is determined by a spatial distribution of the sensor cluster;

[0026] The junction of the primary trunk and the secondary branch is provided with a capacitive coupling node, and low-loss transmission of a pulse signal is realized through impedance matching;

[0027] The fractal network has self-repairing characteristics, and when local fracture occurs, the electrically conductive path is reconstructed through electrochemical migration of silver nanoparticles.

[0028] As a preferred scheme of the assembled enamel tank state detection system of the application, wherein:

[0029] The thermoelectric power generation adopts a curved surface self-adaptive thermoelectric structure, comprising: a flexible thermoelectric arm array is formed by a Bi2Te3 / Sb2Te3 heterostructure folded into a serpentine unit, and forms a closed loop along the circumference of the tank body, the hot end is coupled with the inner wall of the tank body through a graphene heat conduction film, and the cold end is connected with a radiating micro heat dissipation fin;

[0030] The phase change energy storage leveling layer fills paraffin-carbon nanotube composite phase change material between the cold and hot ends, and buffers temperature fluctuations through solid-liquid phase change;

[0031] The contact pressure self-adjusting mechanism adopts a shape memory alloy spring, which dynamically adjusts the contact pressure of the hot end according to the curvature of the tank body surface.

[0032] As a preferred scheme of the assembled enamel tank state detection system of the application, wherein:

[0033] The wireless charging embedded magnetic power supply adopts a magnetoelectric composite topology;

[0034] The magnetoelectric composite topology includes a sub-domain type magnetic attraction array, dynamic magnetic force compensation and thermal-electricity collaborative management;

[0035] The sub-domain type magnetic attraction array includes an outer ring and a central region, the outer ring is arranged with a neodymium iron boron permanent magnet to form a gradient magnetic field, and the central region is embedded with a planar spiral coil to form resonant coupling with an external charging base;

[0036] The dynamic magnetic force compensation monitors the magnetic attraction gap in real time through a Hall sensor array, and an electromagnetic auxiliary coil dynamically compensates the magnetic force according to the gap value;

[0037] The thermal-electricity collaborative management integrates a micro heat pipe on the back plate of the wireless charging module to guide the heat generated by the coil to the cold end of the thermoelectric power generation, forming an energy recycling chain.

[0038] As a preferred scheme of the assembled enamel tank state detection system of the application, wherein:

[0039] The inner wall corrosion diagnosis adopts a segmented color gradient coding, which divides the inner wall surface into a plurality of equally spaced annular regions, each region is provided with a unique color code formed by mixing two or more basic colors, and the color codes of adjacent regions are connected through a gradual color transition;

[0040] The mixed proportion of the color code is associated with the axial position coordinates of the annular area, so that when corrosion occurs, the color code can generate an identifiable color peeling feature due to the damage of the film layer.

[0041] As a preferred scheme of the assembled enamel tank body state detection system of the application, wherein:

[0042] The inner wall corrosion diagnosis further comprises: collecting the reflection spectrum data of the corrosion area by multi-spectral imaging, and differentially comparing the detected abnormal color code with the original coded data by establishing a color-position mapping database;

[0043] For the corrosion boundary of the gradual color transition section, an edge fusion algorithm is used to compensate and calculate the attenuation gradient of adjacent color codes, and a topological correlation rule between annular areas is introduced to map discrete corrosion points to a three-dimensional polar coordinate system, and finally output the corrosion area.

[0044] As a preferred scheme of the assembled enamel tank body state detection system of the application, wherein:

[0045] The coded film is pre-fabricated at the interface between the metal base and the enamel layer by silk screen printing, so that when the corrosion penetrates the enamel layer, the underlying color code is directly exposed;

[0046] In the detection stage, a telescopic guide rail carries a linear array sensor to scan along the axial direction of the tank body in a spiral manner, and the data of the tank pressure sensor is synchronously combined, so that when a local color code anomaly is detected, an ultrasonic probe for wall thickness is automatically triggered for secondary verification.

[0047] The application has the following beneficial effects:

[0048] Through the regular polygon dense packing and spiral winding layout of the three-layer heterogeneous sensor network, full-dimensional coverage of the tank body surface stress, strain and electromagnetic signals is realized, the typing conductive network constructed by the synaptic network is combined, the pulse timing analysis capability of the biological neural network is simulated, the spatiotemporal resolution and feature extraction efficiency of the defect signal are significantly improved, and the enamel tank body micro-cracks and micron-level corrosion pits are accurately and quickly identified.

[0049] The segmented color gradient coded film is integrated at the interface between the metal base and the enamel layer, and color code peeling is triggered after corrosion penetration, and the three-dimensional polar coordinate accurate positioning of the corrosion position is realized by combining the multi-spectral imaging and edge fusion algorithm. BRIEF DESCRIPTION OF DRAWINGS

[0050] In order to more clearly illustrate the technical solutions of the embodiments of the application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creating labor intensity. Among them:

[0051] Figure 1 The tank topology diagram of the assembled enamel tank state detection system of the application;

[0052] Figure 2 The inner wall corrosion diagnosis method flowchart of the assembled enamel tank state detection system of the application;

[0053] Figure 3 The enamel pipe outer surface structure schematic diagram of the assembled enamel tank state detection system of the application.

[0054] The figure mark: 1, piezoelectric film array; 2, regular polygon piezoelectric film; 3, fiber Bragg grating; 4, differential eddy current probe; 5, fiber Bragg grating array; 6, electromagnetic eddy array. DETAILED DESCRIPTION

[0055] In order to make the above objects, features and advantages of the application more obvious and easy to understand, the specific embodiments of the application will be described in detail below with reference to the accompanying drawings.

[0056] In the following description, a lot of specific details are set forth in order to facilitate a thorough understanding of the application, but the application can also be implemented in other ways different from those described herein, and those skilled in the art can make similar generalizations without departing from the spirit of the application, therefore the application is not limited to the specific embodiments disclosed below.

[0057] Secondly, the "one embodiment" or "embodiment" referred to herein means that the specific features, structures or characteristics can be included in at least one implementation of the application. "In one embodiment" appearing in different places in this specification does not mean the same embodiment, nor is it an independent or alternative embodiment that excludes other embodiments.

[0058] Embodiment one

[0059] As shown in the figure, the assembled enamel tank state detection system comprises: Figure 1 The three-dimensional heterogeneous sensor group sets up a three-dimensional heterogeneous sensor network, which is placed on the surface of the enamel tank by sticking, forming a biological neural network sensing system;

[0060] The three-dimensional heterogeneous sensor network comprises a three-layer stacked structure, and the three-layer stacked structure comprises a surface layer, an intermediate layer and a bottom layer.

[0061] A specific implementation method of a three-layer heterogeneous sensor network comprises:

[0062]

[0063] ​The edge node integrates a chip-level atomic clock, and distributes timestamps through each sensor sub-node; the piezoelectric film array uses an event-driven ADC to trigger an interrupt when a stress wave threshold is detected, and records the atomic clock timestamp at the time of triggering; the demodulator of the fiber grating samples at a fixed frequency, and the start time of each scanning cycle is aligned with the atomic clock; the eddy current probe obtains a differential signal which is continuously sampled by a high-speed ADC to form an eddy current impedance spectrum, and each frame of data is attached with an atomic clock start timestamp.

[0064] The tank body is divided into three-dimensional grid units. Each grid unit receives surface layer, middle layer and bottom layer data.

[0065] The surface layer data is the piezoelectric pulse density, reflecting the surface stress wave intensity; the middle layer is the fiber strain gradient data, representing shear deformation; the bottom layer is the eddy current conductivity change data, indicating subsurface defects; the damage probability of each grid is calculated by a weighted scoring mechanism to generate a three-dimensional damage.

[0066] Further, all sensors access a synchronous controller with an atomic clock, and each sensor data packet is attached with four sets of time tags, including the start time of acquisition, the transmission delay compensation time, the edge node receiving time, and the globally unified timestamp.

[0067] The spatial mapping step first pre-processes the data, then performs spatial coordinate conversion on the processed data, and finally performs grid fusion.

[0068] Further, the data preprocessing includes filtering environmental vibration noise from the piezoelectric signal, compensating for temperature drift from the fiber strain data, and calibrating the probe lift-off effect from the eddy current data.

[0069] Further, the piezoelectric unit is mapped to a pre-set polar coordinate system according to a pre-stored position table, the fiber strain point is converted to a strain point through a guide slot scale and mapped to a polar coordinate, and the eddy current probe coordinates are fed back in real time by a mechanical arm.

[0070] Further, the grid fusion divides the tank body into a three-dimensional grid, and each grid integrates the data scores of the three sensors.

[0071] When multiple piezoelectric sensors detect stress waves generated by the same crack, the wave source position is deduced by the pulse arrival time difference, and a time difference-space distance conversion model is established by combining the sound wave propagation speed in the tank body material. The time difference-space distance conversion model is a commonly used physical calculation method for calculating the sound wave propagation distance within a certain time difference value.

[0072] The multi-modal data is intercepted in cycles of 1ms, the piezoelectric data corresponds to the surface stress distribution, the fiber data corresponds to the three-dimensional strain field reconstruction, and the eddy current data corresponds to the subsurface defect mapping.

[0073] Defect mapping rule implementation methods include spatial mapping methods and quantitative correlation formulas;

[0074] Furthermore, the spatial mapping method includes axial mapping (Z-axis) extending upwards and downwards from the midpoint of the crack as the detection range; circumferential mapping (θ-axis) using the circumferential range of the crack as the associated region; and radial mapping of the surface crack to the eddy current detection layer, where the surface crack data is obtained by the fiber strain layer.

[0075] Furthermore, the quantitative correlation formulas include crack projection overlap = (θ-Z projection of eddy current anomaly zone ∩ θ-Z projection of surface crack) / surface crack projection area; strain gradient calculation = (strain value at crack tip - strain value at crack middle) / distance.

[0076] The surface layer is a piezoelectric film array, densely packed in regular polygons on the surface of the enamel can;

[0077] like Figure 3 As shown, it includes a piezoelectric film array 1, a fiber grating array 5, and an electromagnetic eddy current array 6, forming a three-dimensional three-layer structure.

[0078] Furthermore, a regular polygonal piezoelectric film 2 is laid flat on the outer surface of the enamel can to form a piezoelectric film array 1;

[0079] The fiber grating 3 is formed by three-dimensional spiral winding to form the fiber grating array 5.

[0080] Miniaturized electromagnetic coils form a differential eddy current probe 4, and multiple differential eddy current probes 4 form an electromagnetic eddy current array 6.

[0081] The piezoelectric film array is directly attached to the outer surface of the enamel tank, and the surface is sputtered interdigitated electrodes, which can adopt a polygonal honeycomb dense structure.

[0082] Furthermore, the piezoelectric film array is used to capture surface mechanical vibrations in real time and detect the resonant frequency shift of the tank structure.

[0083] In this application, a preferred piezoelectric film array can be made of flexible piezoelectric material with a surface coated with an anti-corrosion insulating layer to adapt to the high temperature and humid environment of the enamel tank.

[0084] Furthermore, each regular polygonal unit is arranged in a spiral pattern to cover the curved surface of the tank, eliminating detection blind spots.

[0085] Furthermore, the upper electrode of the piezoelectric film array can be made of serpentine silver nanowire mesh or other mesh materials to reduce mechanical stress concentration, and the lower electrode fully covers the aluminum foil substrate to form a uniform electric field distribution.

[0086] Each piezoelectric unit is connected to the edge node via silver paste wires. The wire paths extend along the vertices of regular polygons, and fractal routing is used to reduce electromagnetic interference.

[0087] The working principle of the piezoelectric film array includes:

[0088] When the tank surface produces mechanical vibration due to corrosion, cracks or external impact, the crystal structure of the piezoelectric film is deformed, causing the internal polarization charge to redistribute.

[0089] Each piezoelectric unit is connected to a comparator circuit with a preset dynamic threshold, and a pulse is triggered only when the signal amplitude exceeds the threshold. The time when the pulse occurs corresponds to the arrival time of the stress wave, and the time stamp is recorded through the edge node clock.

[0090] The piezoelectric film array realizes high-resolution sensing of the dynamic stress on the enamel tank surface through the combination of material optimization, topological layout and pulse coding technology. Its time pulse sequence not only carries the spatiotemporal information of damage, but also provides a core data source for early corrosion and crack positioning through pulse timing correlation analysis inspired by biological neural networks.

[0091] The intermediate layer is a fiber grating, which is wound in a three-dimensional spiral, and the pitch of the three-dimensional spiral is determined by a regular polygon;

[0092] The intermediate layer is a fiber grating array embedded in a flexible substrate. Further, a single fiber of the fiber grating array is connected to multiple sensors and wound in a spiral path to cover X, Y and Z axis strains.

[0093] Specifically, the core of the fiber grating is a special treated fiber with a periodic grating engraved inside. When the external environment changes, the physical properties of the grating change, causing the wavelength of the reflected light to shift. By measuring this wavelength shift, the strain or temperature change experienced by the fiber can be obtained.

[0094] Further, the fiber is wound around the tank in a three-dimensional spiral path to cover the axial, circumferential and radial directions. This spiral structure allows a single fiber to simultaneously sense deformations in different directions, including elongation or contraction along the length of the tank under internal pressure, tank twisting due to external loads, and expansion or collapse due to internal and external pressure differences.

[0095] Further, the pitch of the spiral is determined by the size of the regular polygon units of the surface piezoelectric film. For example, if the side length of the regular polygon is A mm and the pitch is B mm, the spiral path is aligned with the surface sensors to form a spatially matched detection network, avoiding data misplacement.

[0096] Multiple microgratings are connected in series on a single fiber to form a dense detection node, and each grating is assigned a unique reflection wavelength to distinguish data from different positions.

[0097] The intermediate layer is used to monitor the deformation gradient distribution of the tank and detect the shear stress at the interface between the enamel and the substrate, compensating for the interference of temperature on the piezoelectric signal.

[0098] The bottom layer is a micro electromagnetic coil that constitutes a differential eddy current probe.

[0099] The bottom layer is an electromagnetic eddy current array installed on the surface of the tank body while being isolated by a flexible substrate.

[0100] Further, the eddy current probe adopts a differential coil structure.

[0101] Further, the bottom layer is used to detect metal matrix corrosion, identify hidden cracks under the enamel layer, and evaluate changes in coating thickness.

[0102] The three layers of data are mapped in space to generate a three-dimensional damage topology map for locating surface crack propagation paths and internal corrosion areas.

[0103] Specifically, the specific implementation method of the three-dimensional damage topology map includes:

[0104] The three layers of data generally correspond to three types of detection data with different dimensions:

[0105] The first layer outputs surface point cloud coordinates (X, Y, Z) and geometric parameters such as crack width and direction through surface topography data from a piezoelectric film array.

[0106] The second layer detects subsurface defects through subsurface defect data from an eddy current sensor, and outputs defect depth Z-axis offset, cross-sectional size, and expansion angle.

[0107] The third layer outputs a body data matrix reflecting the spatial position and morphology of the corrosion area through internal corrosion data from a fiber Bragg grating.

[0108] Further, the specific implementation method of the spatial mapping includes:

[0109] A cylindrical coordinate system is established with the geometric center of the target carrier as the origin.

[0110] A global three-dimensional coordinate system (X, Y, Z) is established based on the CAD model of the enamel tank body.

[0111] The surface layer is piezoelectric film point cloud data (X, Y, Z) that is registered with the three-dimensional surface of the tank body through iterative closest points.

[0112] The subsurface layer is eddy current detection data that is mapped to the global coordinate system through interpolation based on the corresponding surface point coordinates.

[0113] The internal layer is fiber Bragg grating strain data that is converted to a three-dimensional strain field through tank gridding and superimposed on the global coordinate system.

[0114] Time-space synchronization embeds all sensor data in a unified timestamp.

[0115] The modeling of the damage of the enamel tank includes surface crack modeling, subsurface defect modeling and internal corrosion modeling.

[0116] The specific implementation methods of the surface crack modeling, the subsurface defect modeling and the internal corrosion modeling are as follows:

[0117] The surface crack modeling is implemented by segmenting a crack point cloud of a piezoelectric film array, extracting a crack contour point set, fitting a crack direction based on the crack contour point set, calculating a width, comparing historical point cloud data, tracking crack tip displacement by using an optical flow method, and generating a crack propagation vector field.

[0118] The subsurface defect modeling is implemented by solving Maxwell equations by using a finite element method, converting eddy current impedance changes into equivalent geometric parameters of subsurface defects, including depth and cross-sectional ellipse major axis / minor axis, converting the defect geometric parameters into a three-dimensional ellipsoid, and embedding the three-dimensional ellipsoid into a global coordinate system.

[0119] The internal corrosion modeling is implemented by establishing a corrosion area strain feature library, including material loss caused by corrosion, and alternating distribution of local strain in tension and compression, and by setting a classifier to segment fiber Bragg grating strain field data into a normal area, a corrosion transition area and a corrosion core area.

[0120] In the present application, a preferred specific implementation method of establishing a spatial correlation rule and constructing a three-dimensional topology map can be selected as follows: the spatial correlation rule construction includes surface-subsurface correlation, subsurface-internal correlation and dynamic weight distribution.

[0121] In the surface-subsurface correlation, if there is a subsurface defect voxel under the crack tip, it is determined that the crack expands internally, and the crack depth prediction value is corrected.

[0122] In the subsurface-internal correlation, when a subsurface defect voxel and a corrosion transition area voxel spatially overlap, it is determined that the corrosion induces subsurface peeling, and the risk level of the area is improved.

[0123] The dynamic weight distribution dynamically adjusts the weight of each layer of data in the fusion according to the sensor confidence.

[0124] The construction method of the three-dimensional topology map includes storing damage information in a global coordinate system, and each node contains a surface crack probability, a subsurface defect size, a corrosion level and a risk comprehensive score.

[0125] The crack path positioning predicts the crack path of the enamel tank by combining the current crack direction and the internal corrosion distribution, and the future crack direction tends to be in a position where the internal corrosion is serious.

[0126] The corrosion hotspot positioning performs cluster analysis on corrosion voxels, and extracts the center coordinates of the largest connected domain as a maintenance priority area.

[0127] If there are enough corrosion points in the neighborhood radius of a certain point of the enamel tank, the area is considered to be a high-density corrosion area, and a cluster is expanded, a cluster is expanded through density-connected points, and points that cannot be attributed to any cluster are considered as noise points.

[0128] The damage report includes a list of crack location, length, depth, corrosion volume, distribution, risk level.

[0129] The biological neural network perception system includes a synaptic network, and the synaptic network is constructed as a typed conductive network based on a flexible substrate.

[0130] The typed conductive network includes a primary trunk and a secondary branch, the primary trunk is used to connect a plurality of sensor clusters, and the secondary branch is used to connect a single sensing unit.

[0131] The biological neural network working method includes: a piezoelectric film array generates a time pulse sequence, a fiber grating outputs a frequency modulation signal, electromagnetic data is converted into pulse intensity, and an edge node performs pulse timing correlation analysis.

[0132] The primary trunk is composed of a cross-linked structure of silver nanowire and polyurethane composite material, and extends along the curvature direction of the enamel tank body to form a closed loop path.

[0133] Specifically, the primary trunk connects a plurality of sensor clusters, that is, a collection of a plurality of sensing units, and is used for cross-area signal aggregation and distribution.

[0134] The primary trunk extends along the curvature direction of the target carrier such as the enamel tank body to form a closed loop path, adapts to a complex curved surface environment, ensures structural stability and signal transmission redundancy, and avoids global failure caused by single-point fracture.

[0135] The primary trunk can be composed of a cross-linked structure of silver nanowire and polyurethane composite material, and the flexibility of polyurethane is matched with the surface deformation, and the high conductivity of silver nanowire ensures low impedance signal transmission.

[0136] The primary trunk carries mixed signals of a plurality of sensor clusters, including time pulses of piezoelectric films, frequency modulation signals of fiber gratings, and pulse intensities of electromagnetic data, and the closed loop path is bidirectional signal flow.

[0137] The secondary branch diverges from the primary trunk at a certain angle, and the branch density is determined by the spatial distribution of the sensor clusters.

[0138] Specifically, the secondary branch diverges from the primary trunk and directly connects a single sensing unit, such as a piezoelectric film, an optical fiber Bragg grating, etc. The secondary branch extends from the primary trunk at a certain angle, and the angle range balances the signal transmission efficiency and spatial distribution density. The angle is prevented from being too small to cause congestion of the branch or too large to increase the signal transmission distance loss. The branch density is dynamically adjusted by the spatial distribution of the sensor cluster to increase the branch density in the high sensitivity area.

[0139] The junction of the primary trunk and the secondary branch is provided with a capacitive coupling node, and low-loss transmission of the pulse signal is achieved through impedance matching.

[0140] Further, at the connection point of the primary trunk and the secondary branch, signal coupling is achieved through a micro-structure capacitor. The high-frequency low-impedance characteristic of the capacitor is used to reduce ohmic loss in pulse signal transmission. By adjusting the ratio of the branch diameter to the cross-sectional area of the main trunk, the branch input impedance is matched with the characteristic impedance of the main trunk, and signal reflection is reduced.

[0141] The fractal network has a self-repairing characteristic. When a local fracture occurs, the electrically conductive path is reconstructed through electrochemical migration of silver nanoparticles.

[0142] Further, when the branch or the main trunk is fractured due to mechanical stress, the silver nanoparticles at the fracture site undergo a dissolution-deposition process to reconstruct the electrically conductive path under the action of electrochemistry. If anodic dissolution occurs, Ag at the fracture end is oxidized to Ag + into the electrolyte; if cathodic deposition occurs, Ag + is reduced to Ag at the other end to form a nano-bridge;

[0143] The primary trunk and the secondary branch are designed through a type of electrically conductive network structure, material function synergy, and a biological signal mechanism to construct a bionic neural network with high-efficiency transmission, environmental adaptability, and self-maintenance capability. It is especially suitable for intelligent monitoring scenarios of curved devices such as enamel tanks, and realizes neural signal processing from local sensing units to edge computing nodes.

[0144] The energy supply unit includes a thermoelectric generator and a wireless charging embedded magnetic attraction structure, which double-ensures power supply;

[0145] The thermoelectric generator adopts a curved surface self-adaptive thermoelectric structure, which includes:

[0146] The flexible thermoelectric arm array is composed of Bi2Te3 / Sb2Te3 heterostructure serpentine folding units, which form a closed loop along the circumference of the tank. The hot end is coupled with the inner wall of the tank through a graphene heat conduction film, and the cold end is connected with a radiating micro heat dissipation fin, which expands the surface area by 8 times.

[0147] The phase change energy storage leveling layer fills paraffin-carbon nanotube composite phase change material between the hot end and the cold end, and buffers temperature fluctuations through solid-liquid phase change.

[0148] The contact pressure self-adjusting mechanism adopts a shape memory alloy spring to dynamically adjust the hot end contact pressure according to the curvature of the tank surface, thereby ensuring the stability of the temperature difference interface thermal resistance.

[0149] A specific implementation method of a thermoelectric generator includes:

[0150] The flexible thermoelectric arm array adopts molecular beam epitaxy technology to grow Bi2Te3 / Sb2Te3 heterojunction thin films on a quartz substrate. The thin films need to control the thickness, and the Bi2Te3 layer (n-type) and the Sb2Te3 layer (p-type) are alternately stacked to form a thermoelectric unit.

[0151] The serpentine folding structure cuts a serpentine channel on the thermoelectric thin film, and the single folding unit is arranged in a circumferential direction to form a closed loop circuit. Electrodes are evaporated at both ends of the serpentine arm, and flexible wires are used to connect each thermoelectric unit in series to form a total thermoelectric potential array.

[0152] The serpentine folding structure allows the thermoelectric arm to freely bend on the surface, and cooperates with the spring dynamic pressure adjustment to realize the close fitting of the tank surface, avoiding the fitting gap of the traditional rigid thermoelectric module.

[0153] The wireless charging embedded magnetic attraction power supply adopts a magneto-electric composite topology;

[0154] The magneto-electric composite topology includes a sub-domain magnetic attraction array, dynamic magnetic force compensation, and thermal-electric collaborative management;

[0155] Nd-Fe-B permanent magnets are arranged in the outer ring annular area to realize rapid adsorption positioning;

[0156] The center functional area embedded planar spiral coil forms resonant coupling with the external charging base. The dynamic magnetic force compensation is monitored in real time by a Hall sensor array. The electromagnetic auxiliary coil dynamically compensates the magnetic force according to the gap value to maintain the adsorption stability while avoiding overpressure damage to the enamel layer.

[0157] The thermal-electric collaborative management integrates a micro heat pipe in the back plate of the wireless charging module to guide the coil heat to the cold end of the thermoelectric generator, forming an energy recycling chain.

[0158] A wireless charging embedded magnetic attraction structure includes processing multiple cylindrical grooves on the base while fixing permanent magnets, and covering the surface with a flexible magnetic isolation layer to avoid magnetic short circuit and prevent scratching the enamel layer.

[0159] The center functional area is a multi-layer stacked structure, including multiple single-layer coil windings. The single-layer coil matches the external base coil parameters, and the layers are isolated by a thin film, and the whole is packaged in a silica gel protective layer.

[0160] A specific implementation method of dynamic magnetic force compensation includes:

[0161] A plurality of high-precision Hall sensors are symmetrically arranged at the four corners of the bottom surface of the magnetic suction module, for real-time collection of air gap magnetic field strength, and average gap is calculated through a trigonometric function. The sensors are packaged in micro grooves at the edge of the magnetic suction module, and the surface is covered with transparent epoxy resin to prevent dust from interfering with the magnetic field signal.

[0162] The control logic is that when the average gap decreases, the control module increases the auxiliary coil current to enhance the adsorption force; when the surface pressure of the tank body increases beyond the dangerous threshold of the enamel layer, the current is automatically reduced to avoid cracking of the enamel layer under pressure.

[0163] The wireless charging embedded magnetic suction structure realizes the cooperation of high-reliability adsorption, high-efficiency energy transmission and intelligent thermal management, and provides a stable composite energy supply solution for the enamel tank body detection system, which is suitable for harsh industrial environments such as humidity and vibration.

[0164] Embodiment two

[0165] The assembled enamel tank body state detection system further comprises:

[0166] As shown in Figure 2 The inner wall corrosion diagnosis method comprises:

[0167] The inner wall corrosion diagnosis decodes the code of the inner wall corrosion site by coding the protective film, and locates the decoding result.

[0168] Specifically, the step of coding the protective film for the inner wall corrosion diagnosis further comprises: using a segmented color gradient code to divide the inner wall surface into a plurality of equidistant annular regions, setting a unique color code in each region by mixing two or more basic colors, and the color codes of adjacent regions are connected by a gradual color transition; the mixing ratio of the color code is associated with the axial position coordinates of the annular region, and the thickness of the color film is controlled so that when corrosion occurs, the color code produces an identifiable color stripping feature due to the damage of the film layer. This coding method can be recognized by visible light band without additional fluorescent or magnetic markers.

[0169] Further, the positioning process of the decoding result further comprises: using a multispectral imaging device to collect the reflection spectrum data of the corrosion area, and differentiating and comparing the detected abnormal color code with the original coded data by establishing a color-position mapping database; for the corrosion boundary of the gradual color transition section, an edge fusion algorithm is used to compensate and calculate the attenuation gradient of adjacent color codes, and a topological association rule between annular regions is introduced to map discrete corrosion points to a three-dimensional polar coordinate system, and finally output a precise positioning grid map with a corrosion area ratio exceeding 5%.

[0170] Further, before the enamel is sintered into shape, the coded film is pre-fabricated at the interface between the metal base and the enamel layer by silk-screen printing, so that the color code of the bottom layer is directly exposed after the corrosion penetrates the enamel layer; in the detection stage, the telescopic guide rail carries the linear array sensor to scan along the axial direction of the tank body in a spiral manner, and the data of the tank pressure sensor are synchronously combined, when the local color code anomaly is detected, the wall thickness ultrasonic probe is automatically triggered for secondary verification, and the positioning coordinates and corrosion grade classification results are transmitted to the external monitoring terminal through the wireless radio frequency module.

[0171] Further, two functional films are added between the metal base and the enamel layer: a bottom original segmented color code layer and a middle zinc-based fluorescent sensitive layer fluorescent dye.

[0172] The detection principle includes early corrosion detection and late corrosion detection.

[0173] In early corrosion detection, the enamel does not penetrate, and when the corrosion medium penetrates the enamel microcrack, ZnO reacts to generate Zn 2+ , triggering the quenching of fluorescent dye, and local dark spots can be seen under ultraviolet light.

[0174] In late corrosion detection, when the enamel penetrates and exposes the color code layer, the color anomaly is identified by a multispectral camera.

[0175] An adaptive corrosion pattern model is established, and the corrosion pattern of the enamel tank body is adaptively identified through a feature library and a dynamic matching algorithm.

[0176] The feature library constructs a pre-stored spectral attenuation curve of a typical corrosion pattern, and the spectral attenuation curve is measured by experiment to have an exponential distribution, a linear attenuation of a gap corrosion, and a superimposed Gaussian noise.

[0177] Further, after the dynamic matching algorithm detects the color code abnormal area, the reflection spectrum curve thereof is extracted, similarity calculation is performed with the feature library, and the corrosion boundary is reconstructed by selecting the best matching model.

[0178] Further, the eddy current probe is used to detect the subsurface conductivity change, and the micro ultrasonic thickness gauge is used to measure the local enamel layer thickness, and when the color code abnormal area meets the following conditions, it is determined as effective corrosion.

[0179] A specific implementation method of inner wall corrosion diagnosis includes:

[0180] The segmented color gradient coding divides the inner wall of the tank body into N annular regions along the axial direction at equal intervals, and each region corresponds to an axial coordinate z_i=i×50, (i=1, 2,..., N), and is uniformly distributed in a circumferential direction of 360°.

[0181] RGB three primary colors are used, and the color code of each region is uniquely determined by the axial coordinate z_i, and the color codes of adjacent regions are transitioned through gradient color to form a continuous color gradient band.

[0182] The screen printing pre-encoding film adopts a laser engraving method to make an annular hollow pattern on a stainless steel screen,

[0183] The corrosion area decoding includes multispectral imaging data acquisition, chrominance position database and gradual area corrosion boundary processing.

[0184] The multispectral imaging data acquisition is configured to load a linear array CCD sensor on a telescopic guide rail to perform spiral scanning on the inner wall, and synchronously collect inner wall reflection spectrum data. Before scanning, a standard color card is used for white balance correction to establish a mapping relationship between spectral reflectance and RGB values.

[0185] The chrominance position database collects 100 groups of spectral data of each annular area of the inner wall of the newly manufactured tank body, calculates average RGB values and CIELAB color space coordinates, establishes a three-dimensional database of “axial coordinates and circumferential angle and standard color code”, and if color difference abnormalities occur, marks them as corrosion suspicious areas and triggers secondary verification.

[0186] The gradual area corrosion boundary processing is that in the gradual transition area between adjacent annular areas of the tank body, the corrosion boundary is not a clear straight line, but a fuzzy band with gradually changing colors according to different corrosion depths.

[0187] If the color codes of the two adjacent standard areas are “area 1 color” and “area 2 color” respectively, when corrosion occurs in the gradual area between them, the actual detected color is a mixture of the two colors, the shallower the corrosion, the closer the color to “area 1 color”, and the deeper the corrosion, the closer the color to “area 2 color”.

[0188] The corrosion depth is determined by ultrasonic thickness measurement data, and the depth is converted into a 0-1 ratio value, for example, if the corrosion depth increases, the depth ratio increases, and the mixing degree of the two standard colors is adjusted by the depth ratio. One preferred solution is that if the ratio value is 0, it is completely “area 1 color”, if the ratio value is 1, it is completely “area 2 color”, and intermediate values are mixed in proportion to restore the true color transition rule of the gradual area and eliminate recognition errors caused by boundary fuzziness during detection.

[0189] The tank body is a cylindrical inner wall, in order to accurately locate the corrosion area, the curved surface needs to be converted into a coordinate system convenient for calculation; the fixed radius r of the tank body and the circumferential angle θ take a generatrix of the tank body as the 0° starting point, and the clockwise scanning division of an angle unit will obtain multiple discrete corrosion points. Through the above polar coordinates, the circumferential angle and axial height of each point are corresponded to the specific position of the cylindrical curved surface. Then, according to the distribution rule of these points, they are “connected” into a continuous area by algorithm to form a complete corrosion contour.

[0190] In the fitted continuous area, the proportion of the statistical corrosion area to the total area of the annular area is calculated, and through accurate coordinate positioning and contour fitting, a three-dimensional grid map containing corrosion position and area is finally output, which intuitively displays the corrosion severity.

[0191] Importantly, it should be noted that the constructions and arrangements of the present application shown in the various different exemplary embodiments are merely illustrative. Although only two embodiments have been described in detail herein, those skilled in the art will appreciate that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter described in this disclosure. For example, the dimensions, sizes, structures, shapes and proportions of the various elements, as well as the parameters values (e.g., temperature, pressure, etc.), mounting arrangements, materials, colors, orientations, etc. can be varied. For example, elements shown as integrally formed can be constructed of multiple parts or elements, the position of elements can be reversed or otherwise varied, and the nature or number of elements or positions can be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps can be varied or re-sequenced without departing from the subject matter described herein. Any "means plus function" clauses are intended to cover the structures described herein as performing claimed functions and not only structural equivalents, but also equivalent structures. Other substitutions, modifications, changes, and omissions can be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the present application. Accordingly, the present application is not limited to the particular embodiments described herein, but extends to all structures that would fall within the scope of the appended claims.

[0192] Also, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation can not be described (i.e., those unrelated to the presently contemplated best mode of carrying out the application, or those unrelated to enabling the claimed application).

[0193] It should be appreciated that in the development of any actual implementation, as in any engineering or design project, numerous implementation-specific decisions can be made. Such development efforts might be complex and time-consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0194] It should be noted that the above examples are only used to illustrate the technical solutions of the present application but not to limit the present application, and although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the spirit and scope of the present application, and all should be included in the scope of the claims of the present application.

Claims

1. A system for detecting the state of a fabricated enamel tank, characterized by, The system comprises: A three-dimensional heterogeneous sensor network is arranged by pasting on the surface of the enamel tank to form a biological neural network perception system; The three-dimensional heterogeneous sensor network comprises a three-layer stack structure, which comprises a surface layer, an intermediate layer and a bottom layer; The surface layer is a piezoelectric film array densely packed on the surface of the enamel tank in the form of regular polygons; The intermediate layer is a fiber grating wound in a three-dimensional spiral, and the pitch of the three-dimensional spiral is determined by the regular polygon; The bottom layer is a differential eddy current probe composed of miniaturized electromagnetic coils; The energy supply unit includes thermoelectric power generation and wireless charging embedded magnetic power supply, which double ensures the power supply; The inner wall corrosion diagnosis decodes the code of the inner wall corrosion site by coding the protective film, and locodes the decoding result; The inner wall corrosion diagnosis adopts segmented color gradient coding to divide the inner wall surface into a plurality of equidistant annular regions, each region is provided with a unique color code formed by mixing two or more basic colors, and the color codes of adjacent regions are connected by gradient color transition; The mixing ratio of the color code is associated with the axial position coordinates of the annular region, so that when corrosion occurs, the color code will produce an identifiable color stripping feature due to the damage of the film layer.

2. The assembled enamel tank state detection system according to claim 1, characterized in that: The biological neural network perception system comprises a synaptic network, and the synaptic network constructs a typed conductive network with a flexible substrate; The typed conductive network comprises a primary trunk and a secondary branch, the primary trunk is used for connecting a plurality of sensor clusters, and the secondary branch is used for connecting a single sensing unit; The biological neural network working method comprises: the piezoelectric film array generates a time pulse sequence, the fiber grating outputs a frequency modulation signal, the electromagnetic data is converted into pulse intensity, and the edge node performs pulse time sequence correlation analysis.

3. The assembled enamel tank state detection system according to claim 1, characterized in that: The sensor network realizes multi-modal data fusion through the cooperative working mechanism of the three-layer stack structure, specifically including: The surface layer piezoelectric film array detects the dynamic stress wave on the surface of the enamel tank through the regular polygon dense packing configuration, and converts mechanical vibration into electric pulse signal; The intermediate layer fiber grating is based on three-dimensional spiral winding, and the pitch of the three-dimensional spiral winding is determined by the regular polygon, which is used for real-time monitoring of the shear strain distribution of the tank; The bottom layer differential eddy current probe extracts the electromagnetic characteristic parameters of the metal matrix inside the tank through the complementary layout of the miniaturized electromagnetic coils; The three-layer data are fused through space-time registration to generate a three-dimensional damage topology map, which is used for positioning the surface crack propagation path and the internal corrosion area.

4. The assembled enamel tank state detection system according to claim 2, characterized in that: The primary trunk is composed of a cross-linked structure of a composite material, and extends along the curvature direction of the enamel tank to form a closed loop path; The secondary branch diverges from the primary trunk at an included angle, and the branch density is determined by the spatial distribution of the sensor cluster; The junction of the primary trunk and the secondary branch is provided with a capacitive coupling node, and the low-loss transmission of the pulse signal is realized through impedance matching.

5. The assembled enamel tank state detection system according to claim 4, characterized in that: The thermoelectric power generation adopts a curved surface self-adaptive thermoelectric structure, including: a flexible thermoelectric arm array is formed by Bi2Te3 / Sb2Te3 heterostructure serpentine folding units, forming a closed loop along the circumference of the tank, the hot end is coupled with the inner wall of the tank through a graphene heat conduction film, and the cold end is connected with a radiating micro heat dissipation fin; The phase change energy storage leveling layer fills paraffin-carbon nanotube composite phase change material between the cold and hot ends, and buffers temperature fluctuations through solid-liquid phase change; The contact pressure self-adjusting mechanism adopts a shape memory alloy spring to dynamically adjust the contact pressure of the hot end according to the curvature of the tank surface.

6. The assembled enamel tank state detection system according to claim 5, characterized in that: The wireless charging embedded magnetic power supply adopts a magnetoelectric composite topology; The magnetoelectric composite topology includes a domain type magnetic attraction array, dynamic magnetic force compensation, and thermal-electricity collaborative management; The domain type magnetic attraction array includes an outer ring-shaped area and a central area, the outer ring-shaped area is arranged with a neodymium iron boron permanent magnet to form a gradient magnetic field, and the central area is embedded with a planar spiral coil to form resonant coupling with an external charging base; The dynamic magnetic force compensation monitors the magnetic attraction gap in real time through a Hall sensor array, and an electromagnetic auxiliary coil dynamically compensates the magnetic force according to the gap value; The thermal-electricity collaborative management integrates a micro heat pipe on the back plate of the wireless charging module to guide the heat generated by the coil to the cold end of the thermoelectric power generation, forming an energy recycling chain.

7. The assembled enamel tank state detection system according to claim 6, characterized in that: The inner wall corrosion diagnosis further includes: multi-spectral imaging collects the reflection spectrum data of the corrosion area, and through the establishment of a colorimetric-position mapping database, the detected abnormal color code is differentially compared with the original coded data; For the corrosion boundary of the gradual color transition section, an edge fusion algorithm is used to compensate and calculate the attenuation gradient of adjacent color codes, and a topological correlation rule between the annular areas is introduced to map the discrete corrosion points to a three-dimensional polar coordinate system, and finally output the corrosion area.

8. The assembled enamel tank state detection system according to claim 7, characterized in that: The coded film is pre-fabricated at the interface between the metal substrate and the enamel layer by silk screen printing, so that when the corrosion penetrates the enamel layer, the bottom color code is directly exposed; In the detection stage, a telescopic guide rail carries a linear array sensor to scan along the axial spiral of the tank, and synchronously combines with the tank pressure sensor data, when detecting local color code abnormalities, automatically triggers the wall thickness ultrasonic probe for secondary verification.

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