Equipment deformation real-time monitoring method and equipment based on optical fiber

Abstract

The invention provides an optical fiber-based equipment deformation real-time monitoring method and equipment, and belongs to the technical field of equipment monitoring, and the method comprises the steps: laying an optical fiber sensor on the surface or in the equipment according to the structural characteristics, stress distribution and deformation expected direction of the to-be-monitored equipment; when the equipment is in a non-deformation state or a known deformation state, collecting initial optical signal data reflected or transmitted by the optical fiber through an optical detector; in the equipment operation process, optical signals are continuously injected into the optical fibers, and the optical signals reflecting equipment deformation are collected in real time and preprocessed; feature parameters related to equipment deformation are extracted from the preprocessed optical signals, and the real-time deformation of the equipment is calculated; comparing the calculated real-time deformation amount with a preset deformation safety threshold value; if the real-time deformation exceeds a safety threshold value, sound-light alarm, short message notification or remote control shutdown is triggered immediately, and deformation data and early warning information are stored in a database. According to the invention, comprehensive data support is provided for state evaluation and fault diagnosis of equipment.

Description

Technical Field

[0001] The present invention belongs to the technical field of equipment monitoring, and in particular relates to a method and equipment for real-time monitoring of equipment deformation based on optical fiber. Background Art

[0002] In many fields, including industrial production and infrastructure construction, equipment deformation directly impacts operational safety and reliability. For example, large bridges, mechanical equipment, and pressure vessels can deform over time due to external forces, temperature fluctuations, and material aging. Failure to promptly detect and address these deformations can lead to equipment failure or even accidents.

[0003] Traditional methods for monitoring equipment deformation primarily include mechanical and electrical measurement. Mechanical measurement methods, such as micrometers and dial indicators, are complex to operate, have low measurement accuracy, and struggle to achieve real-time monitoring. Electrical measurement methods, such as resistance strain gauges, suffer from poor anti-interference capabilities and susceptibility to environmental factors. Therefore, finding a high-precision, real-time, and anti-interference equipment deformation monitoring method is of great practical significance. Summary of the Invention

[0004] The purpose of the present invention is to provide a method and device for real-time monitoring of equipment deformation based on optical fiber, so as to achieve high-precision and real-time monitoring of equipment deformation, timely discover abnormal deformation of the equipment, and ensure the safe operation of the equipment.

[0005] The technical solutions of the present invention are as follows:

[0006] A method for real-time monitoring of equipment deformation based on optical fiber, comprising the following steps:

[0007] According to the structural characteristics, stress distribution and expected deformation direction of the equipment to be monitored, the optical fiber sensors are laid on the surface or inside the equipment in a grid, spiral or along the key stress path;

[0008] When the device is in a state of no deformation or known deformation, preheat the light source and calibrate its performance. Use the calibrated light source to inject a stable light signal into the optical fiber, and use the light detector to collect the initial light signal data reflected or transmitted by the optical fiber.

[0009] During the operation of the equipment, optical signals are continuously injected into the optical fiber, and optical signals reflecting equipment deformation are collected in real time and pre-processed;

[0010] Extracting characteristic parameters related to device deformation from the preprocessed optical signal;

[0011] Calculate the real-time deformation ΔD of the equipment based on the extracted characteristic parameters;

[0012] The calculated real-time deformation ΔD is compared with the preset deformation safety threshold D th Make a comparison;

[0013] If the real-time deformation ΔD exceeds the safety threshold D th , immediately triggering sound and light alarms, SMS notifications or remote control shutdown, and storing deformation data and warning information in the database.

[0014] Furthermore, the initial optical signal data includes the intensity I0, wavelength λ0 and phase of the initial optical signal.

[0015] Furthermore, the collecting of the optical signal reflecting the deformation of the device and preprocessing thereof are specifically as follows:

[0016] During the operation of the device, a high-speed optical detector is used to continuously collect the optical signal reflected or transmitted by the optical fiber at a preset sampling frequency;

[0017] Adopting adaptive filtering algorithm to filter the collected optical signal;

[0018] Comparing the collected real-time optical signal with the initial optical signal data, calculating the deviation between the two, and performing baseline correction on the real-time optical signal;

[0019] The optical signal after filtering and baseline correction is normalized to adjust the amplitude of the optical signal to within a preset standard range.

[0020] Furthermore, characteristic parameters related to device deformation are extracted from the pre-processed optical signal, specifically:

[0021] The pre-processed time-domain optical signal is converted into a frequency-domain signal using a fast Fourier transform to obtain the optical signal's spectrum distribution. The main frequency components of the optical signal are determined by analyzing the spectrum. A phase-locked loop (PLL) is used to track the main frequency of the optical signal in real time. By monitoring the change in the PLL output frequency, the frequency change of the optical signal can be obtained.

[0022] Use a spectrometer to perform spectral analysis on the pre-processed optical signal to obtain the spectral characteristics of the optical signal; compare the characteristic wavelength currently measured with the wavelength of the initial optical signal, and the difference between the two is the wavelength drift;

[0023] An interferometer is used to perform interference measurement on the pre-processed optical signal to form interference fringes. The interference fringes are analyzed to determine the movement of the interference fringes. Based on the amount of movement of the interference fringes and the parameters of the interferometer, the phase change of the optical signal is calculated.

[0024] Furthermore, based on the extracted characteristic parameters, the real-time deformation ΔD of the device is calculated as follows:

[0025]

[0026] Where Δf is the frequency change of the optical signal, Δλ is the wavelength drift, is the phase change, k1, k2, k3 are calibration coefficients.

[0027] Furthermore, the preset deformation safety threshold D th It is determined comprehensively based on the equipment's design standards, historical operating data, and industry safety regulations.

[0028] Furthermore, when laying the optical fiber sensor, a buffer layer is provided between the optical fiber sensor and the surface or interior of the device.

[0029] The present invention also provides an optical fiber-based device for real-time monitoring of device deformation, comprising:

[0030] Fiber optic sensors are used to sense deformation of equipment. They are laid on the surface or inside the equipment in a grid, spiral pattern, or along the critical stress path according to the structural characteristics, stress distribution, and expected deformation direction of the equipment to be monitored.

[0031] A light source module is used to inject a stable light signal into the optical fiber sensor;

[0032] A light detector module is used to collect light signals reflected or transmitted by the optical fiber, including initial light signal data and light signals reflecting device deformation;

[0033] A signal preprocessing module is used to preprocess the collected optical signal reflecting the deformation of the device, including filtering and normalization operations;

[0034] A feature extraction module is used to extract feature parameters related to device deformation from the preprocessed optical signal;

[0035] The deformation calculation module is used to calculate the real-time deformation of the device based on the extracted characteristic parameters;

[0036] Comparison module, used to compare the calculated real-time deformation ΔD with the preset deformation safety threshold D th Make a comparison;

[0037] The early warning and storage module is used to trigger sound and light alarms, SMS notifications or remote control shutdown, and store deformation data and early warning information in the database.

[0038] Compared with the prior art, the present invention has the following advantages:

[0039] Comprehensive monitoring: Through the reasonable laying of optical fiber sensors, comprehensive deformation monitoring of the equipment can be achieved, overcoming the shortcomings of the limited monitoring range of traditional monitoring methods.

[0040] High precision: Fiber optic sensing technology has the characteristics of high sensitivity and high precision, and can accurately measure tiny deformations of equipment.

[0041] Real-time: The real-time data processing and early warning mechanism can promptly detect abnormal deformation of the equipment and provide guarantee for the safe operation of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The accompanying drawings illustrate various embodiments generally by way of example and not limitation, and together with the description and claims, serve to explain embodiments of the invention. Where appropriate, the same reference numerals are used throughout the drawings to refer to the same or similar parts. Such embodiments are illustrative and are not intended to be exhaustive or exclusive of the embodiments of the present apparatus or method.

[0043] Figure 1 A schematic flow chart of the method of the present invention is shown. DETAILED DESCRIPTION

[0044] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0045] like Figure 1 As shown, the present invention provides a method for real-time monitoring of equipment deformation based on optical fiber, comprising:

[0046] Fiber optic sensor installation

[0047] Before installing fiber optic sensors on the equipment to be monitored, a detailed analysis of the equipment's structural characteristics is required. For example, large bridges consist of different components, such as piers and beams. Stress distribution is concentrated at the base of the piers and mid-span of the beams, while deformation is primarily expected to occur in the vertical deflection of the beams and the horizontal displacement of the piers. Based on these characteristics, fiber optic sensors can be laid out in a grid pattern on the beam surface to comprehensively monitor deformation. For piers, fiber optic sensors can be placed along key stress paths (such as the vertical direction).

[0048] During installation, a buffer layer is placed between the fiber optic sensor and the surface or interior of the equipment. This layer can be made of rubber, with its thickness determined by the surface roughness and the expected stress level. For example, for equipment with a rough surface, the buffer layer thickness can be increased to 2-3 mm to minimize damage to the fiber optic sensor while ensuring that the sensor can accurately sense deformation.

[0049] Initial optical signal data collection

[0050] Initial optical signal data collection is performed when the device is in a non-deformed or known deformation state. First, ensure that the light source module injects a stable optical signal into the optical fiber. A wavelength-stable, constant-output-power laser source, such as a distributed feedback (DFB) laser, can be used. Its output wavelength stability can reach ±0.1nm and its output power stability can reach ±0.05dBm.

[0051] The optical detector module is used to collect the initial optical signal data reflected or transmitted by the optical fiber, including the intensity I0, wavelength λ0 and phase of the initial optical signal The light detector can be a high-speed, high-sensitivity photodetector, such as an avalanche photodiode (APD), which has a response speed of nanoseconds and can accurately capture subtle changes in light signals.

[0052] Real-time optical signal acquisition and pre-processed signal acquisition

[0053] During device operation, a high-speed optical detector continuously samples optical signals reflected or transmitted by the optical fiber at a preset sampling frequency. The sampling frequency is set based on the device's expected deformation rate and the characteristics of the optical signal. For example, for devices with a faster deformation rate, the sampling frequency can be set to 100Hz; for devices with a slower deformation rate, the sampling frequency can be appropriately reduced to 10Hz. Filtering: The collected optical signal is filtered using an adaptive filtering algorithm, such as the least mean square (LMS) algorithm. The LMS algorithm automatically adjusts the filter coefficients based on the real-time statistical characteristics of the optical signal, effectively removing random noise and periodic interference signals generated by factors such as environmental interference and light source fluctuations. In practical applications, the LMS algorithm can be implemented by writing corresponding program code. The filter order can be adjusted based on the complexity of the optical signal and is generally set to 32-64 orders. Baseline correction: The collected real-time optical signal is compared with the initial optical signal data, the deviation between the two is calculated, and the real-time optical signal is baseline corrected. Specifically, a program is written in the data processing module to subtract the intensity, wavelength, and phase of the real-time optical signal from the corresponding values of the initial optical signal to obtain an offset value. This offset value is then subtracted from the real-time optical signal to eliminate signal offsets caused by system errors and environmental factors. Normalization processing: Normalization is performed on the filtered and baseline-corrected optical signal, adjusting the amplitude of the optical signal to a preset standard range, such as the (0-1) interval.

[0054] Feature parameter extraction

[0055] Frequency variation Δf extraction: The preprocessed time-domain optical signal is converted into a frequency-domain signal using a fast Fourier transform (FFT) to obtain the optical signal's spectral distribution. Professional signal processing libraries, such as the NumPy library in Python, can be used to implement the FFT algorithm. By analyzing the spectrum, the primary frequency components of the optical signal are determined. A phase-locked loop (PLL) is then used to track the primary frequencies of the optical signal in real time. An integrated PLL chip, such as the CD4046, can be used for the PLL. By monitoring the change in the PLL output frequency, the frequency variation Δf of the optical signal can be obtained.

[0056] Wavelength drift Δλ extraction: A spectrometer is used to perform spectral analysis on the preprocessed optical signal to obtain its spectral characteristics. This spectrometer can be a high-precision fiber optic spectrometer, such as the Ocean Optics HR4000 spectrometer, which offers a wavelength resolution of up to 0.03 nm. In the spectrum, characteristic wavelengths associated with device deformation are identified. Wavelengths that exhibit significant changes in optical signal intensity and are sensitive to device deformation are typically selected as characteristic wavelengths. The currently measured characteristic wavelength is compared with the initial optical signal wavelength λ0; the difference between the two is the wavelength drift. To improve measurement accuracy, multiple measurements can be taken and averaged.

[0057] Phase change Extraction: Use an interferometer to perform interference measurement on the pre-processed light signal to form interference fringes. The interferometer can be a Michelson interferometer. By adjusting the optical path of the interferometer, the light signal forms clear interference fringes. To analyze the interference fringes, image processing techniques such as edge detection algorithms can be used to determine the movement of the interference fringes. Based on the amount of movement of the interference fringes and the parameters of the interferometer, the phase change of the light signal is calculated. The calculation formula is

[0058]

[0059] Where ΔN is the amount of movement of the interference fringes, and λ is the wavelength of light.

[0060] Real-time deformation calculation

[0061] According to the extracted feature parameters, according to the formula

[0062]

[0063] Calculate the real-time deformation ΔD of the device. The calibration coefficients k1, k2, and k3 are determined by performing multiple simulated deformation experiments of different degrees on the device. In the simulated deformation experiment, a high-precision deformation loading device is used to apply a known deformation to the device, and the corresponding characteristic parameters Δf, Δλ, Then, the least squares method is used to fit the optimal values of k1, k2, and k3. In practical applications, the calibration coefficients can be stored in a database, and the deformation calculation module directly calls these coefficients when calculating the real-time deformation.

[0064] Threshold comparison and warning storage

[0065] The calculated real-time deformation ΔD is compared with the preset deformation safety threshold D th For comparison. The preset deformation safety threshold D th Determined based on the equipment's design standards, historical operating data, and industry safety regulations. For example, for bridge equipment, D can be determined by referring to relevant bridge design regulations and previous monitoring data. th value.

[0066] If the real-time deformation ΔD exceeds the safety threshold D th The warning and storage module immediately triggers an audible and visual alarm, SMS notification, or remote shutdown. The audible and visual alarm can be installed near the equipment or in the monitoring room, using an LED indicator and buzzer. SMS notifications can be sent via an SMS gateway, sending warning information to the mobile phones of relevant managers. Remote shutdown can be connected to the equipment's control system, automatically sending a shutdown command when a warning is triggered. Deformation data and warning information are stored in a MySQL database, facilitating subsequent data query and analysis.

[0067] An embodiment of the present invention further provides an optical fiber-based device for real-time monitoring of device deformation, comprising:

[0068] Fiber optic sensors are used to sense deformation of equipment. They are laid on the surface or inside the equipment in a grid, spiral pattern, or along the critical stress path according to the structural characteristics, stress distribution, and expected deformation direction of the equipment to be monitored.

[0069] A light source module is used to inject a stable light signal into the optical fiber sensor;

[0070] A light detector module is used to collect light signals reflected or transmitted by the optical fiber, including initial light signal data and light signals reflecting device deformation;

[0071] A signal preprocessing module is used to preprocess the collected optical signal reflecting the deformation of the device, including filtering and normalization operations;

[0072] A feature extraction module is used to extract feature parameters related to device deformation from the preprocessed optical signal;

[0073] The deformation calculation module is used to calculate the real-time deformation of the device based on the extracted characteristic parameters;

[0074] A comparison module is used to compare the calculated real-time deformation ΔD with a preset deformation safety threshold D_th;

[0075] The early warning and storage module is used to trigger sound and light alarms, SMS notifications or remote control shutdown, and store deformation data and early warning information in the database.

[0076] The above is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field, within the technical scope disclosed by the present invention, can make equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, which should be covered by the scope of protection of the present invention.

Claims

1. A method for real-time monitoring of equipment deformation based on optical fiber, characterized in that: The following steps are involved: According to the structural characteristics, stress distribution and expected deformation direction of the equipment to be monitored, the optical fiber sensors are laid on the surface or inside the equipment in a grid, spiral or along the key stress path; When the device is in a state of no deformation or known deformation, the light source is preheated and performance calibrated. A stable light signal is injected into the optical fiber using the calibrated light source, and the initial light signal data reflected or transmitted by the optical fiber is collected through the light detector. During the operation of the equipment, optical signals are continuously injected into the optical fiber, and optical signals reflecting equipment deformation are collected in real time and pre-processed; Extract characteristic parameters related to device deformation from the pre-processed optical signal, and calculate the real-time deformation ΔD of the device based on the extracted characteristic parameters; The calculated real-time deformation ΔD is compared with the preset deformation safety threshold D th Make a comparison; If the real-time deformation ΔD exceeds the safety threshold D th , immediately triggering sound and light alarms, SMS notifications or remote control shutdown, and storing deformation data and warning information in the database.

2. The optical fiber-based real-time monitoring method for equipment deformation according to claim 1, characterized in that: The initial optical signal data includes the intensity I0, wavelength λ0 and phase of the initial optical signal 3. The optical fiber-based real-time monitoring method for equipment deformation according to claim 1, characterized in that: The collecting of optical signals reflecting device deformation and preprocessing are specifically as follows: During the operation of the device, a high-speed optical detector is used to continuously collect the optical signal reflected or transmitted by the optical fiber at a preset sampling frequency; Adopting adaptive filtering algorithm to filter the collected optical signal; Comparing the collected real-time optical signal with the initial optical signal data, calculating the deviation between the two, and performing baseline correction on the real-time optical signal; The optical signal after filtering and baseline correction is normalized to adjust the amplitude of the optical signal to within a preset standard range.

4. The optical fiber-based real-time monitoring method for equipment deformation according to claim 1, characterized in that: The characteristic parameters related to device deformation are extracted from the preprocessed optical signal: The pre-processed time-domain optical signal is converted into a frequency-domain signal using a fast Fourier transform to obtain the optical signal's spectrum distribution. The main frequency components of the optical signal are determined by analyzing the spectrum. A phase-locked loop (PLL) is used to track the main frequency of the optical signal in real time. By monitoring the change in the PLL output frequency, the frequency change of the optical signal can be obtained. Use a spectrometer to perform spectral analysis on the pre-processed optical signal to obtain the spectral characteristics of the optical signal; compare the characteristic wavelength currently measured with the wavelength of the initial optical signal, and the difference between the two is the wavelength drift; The interferometer is used to perform interference measurement on the pre-processed optical signal to form interference fringes; the interference fringes are analyzed to determine the movement of the interference fringes, and the phase change of the optical signal is calculated based on the amount of movement of the interference fringes and the parameters of the interferometer.

5. The optical fiber-based real-time monitoring method for equipment deformation according to claim 1, characterized in that: According to the extracted characteristic parameters, the real-time deformation ΔD of the device is calculated as follows: Where Δf is the frequency change of the optical signal, Δλ is the wavelength drift, is the phase change, k1, k2, k3 are calibration coefficients.

6. The optical fiber-based real-time monitoring method for equipment deformation according to claim 1, characterized in that: The preset deformation safety threshold D th It is determined comprehensively based on the equipment's design standards, historical operating data, and industry safety regulations.

7. The optical fiber-based real-time monitoring method for equipment deformation according to claim 1, characterized in that: When laying the optical fiber sensor, a buffer layer is provided between the optical fiber sensor and the surface or interior of the device.

8. A real-time monitoring device for equipment deformation based on optical fiber, characterized in that: include: Fiber optic sensors are used to sense deformation of equipment. They are laid on the surface or inside the equipment in a grid, spiral pattern, or along the critical stress path according to the structural characteristics, stress distribution, and expected deformation direction of the equipment to be monitored. A light source module is used to inject a stable light signal into the optical fiber sensor; A light detector module is used to collect light signals reflected or transmitted by the optical fiber, including initial light signal data and light signals reflecting device deformation; A signal preprocessing module is used to preprocess the collected optical signal reflecting the deformation of the device, including filtering and normalization operations; A feature extraction module is used to extract feature parameters related to device deformation from the preprocessed optical signal; The deformation calculation module is used to calculate the real-time deformation of the device based on the extracted characteristic parameters; Comparison module, used to compare the calculated real-time deformation ΔD with the preset deformation safety threshold D th Make a comparison; The early warning and storage module is used to trigger sound and light alarms, SMS notifications or remote control shutdown, and store deformation data and early warning information in the database.

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