Electrolytic tank pipeline impurity real-time detection system and method based on endoscope

Abstract

The invention discloses an endoscope-based electrolytic bath pipeline impurity real-time detection system and method. The system comprises an endoscope module, a pattern transmission processing system and a system linkage module, wherein the endoscope module is controlled to move in a pipeline; the endoscope module comprises an integrated optical module and a mechanical driving module, moves in the pipeline and visually collects impurities in the pipeline; the pattern transmission processing system comprises a control cable and a control processing system, the control cable comprises a signal cable and an optical fiber image transmission bundle, one end of the control cable is connected with the endoscope module, and the control processing system analyzes impurity characteristics of an image transmitted by the integrated optical module in real time based on an algorithm; and the system linkage module triggers grading early warning based on an impurity detection result. By adopting the Hastelloy C276 shell, the sapphire protection lens and the gradient composite coating and combining with the design of the cooling flow channel, the system can stably operate in high-temperature, high-pressure and strong-corrosion environments, and the continuous working life of the probe is more than or equal to 80,000 hours and is prolonged by more than 5 times compared with that of a traditional endoscope.

Description

Technical Field

[0001] The present invention relates to the technical field of electrolytic hydrogen production, and in particular to an endoscope-based real-time detection system and method for impurities in an electrolytic cell pipeline. Background Art

[0002] The electrolyzer is a core piece of equipment in the green hydrogen industry chain, and the cleanliness of its internal piping system has a crucial impact on electrolysis efficiency, gas purity, equipment lifespan, and safety. During the manufacturing, installation, operation, and maintenance of the piping system, unavoidable impurities such as metal debris, welding slag, and polymer particles are inevitably introduced or generated. Furthermore, the wet hydrogen generated by the cathode and anode of the electrolyzer carries a large amount of alkali, potentially carrying electrode coating fragments and seal debris into the downstream separation device. These impurities can not only cause pipeline blockages, catalyst contamination and poisoning, and equipment damage, but more seriously, when metal impurities lodge in the alkali channel inlet and outlet of the electrolyzer's electrode frame, they can cause a short circuit due to the material potential difference, leading to arcing and burning of the electrode plates, and even threatening equipment operation safety. The alkali pipeline connecting the electrolyzer to the separation system is particularly prone to residual impurities during construction, which can flow into the electrolyzer along with the fluid, posing a hidden safety hazard.

[0003] Existing detection technologies are limited by their principles and structural defects and are unable to meet actual needs. Offline disassembly inspection requires stopping the pipeline and disassembling it, and then determining the impurity situation through pressure / flow monitoring or sampling analysis. This method is not only time-consuming and labor-intensive, but also cannot track the dynamic accumulation process of impurities in real time, resulting in delayed problem discovery. Non-destructive testing of the outer wall of the pipeline can only indirectly infer the internal conditions and cannot achieve visual identification and location of impurities. Traditional visual inspection relies on manual operation and is limited by the inspection angle and lighting conditions. The missed detection rate is high, especially for tiny particles with a particle size of less than 0.5mm, which is almost impossible to identify. In addition, due to the insufficient tolerance of the material, conventional endoscopes cannot stably operate in the high temperature (above 80°C), high pressure (above 5MPa) and highly corrosive (pH 0-14) media environment in the electrolytic cell. Frequent equipment replacement further increases operation and maintenance costs and downtime risks.

[0004] The aforementioned technical bottlenecks have led to the long-term dilemma of "delayed detection, high missed detection rate, and poor environmental adaptability" in electrolyzer pipeline impurity detection. This has prevented the timely detection of early hidden dangers, and has also made it difficult to effectively monitor the distribution and migration trends of impurities. This can lead to decreased electrolysis efficiency, shortened equipment life, and even safety accidents. Therefore, there is an urgent need for a new technical solution that can achieve in-situ, real-time, and visual detection of impurities inside the pipeline during normal equipment operation or short shutdowns, without requiring large-scale disassembly of the pipeline, and complete the identification and location of impurities. This will overcome the inherent drawbacks of existing detection methods and ensure the safe and efficient operation of the green hydrogen production system. Summary of the Invention

[0005] The purpose of the present invention is to overcome the defects in the prior art and provide a real-time detection system and method for impurities in electrolytic cell pipelines based on an endoscope.

[0006] To achieve the above object, the technical solution of the present invention is as follows: An endoscope-based real-time detection system for impurities in electrolytic cell pipelines, comprising an endoscope module that is controlled to move in the pipeline, a pattern transmission and processing system, and a system linkage module; The endoscope module includes an integrated optical module and a mechanical drive module, which moves in the pipeline and visually collects impurities in the pipeline; The pattern transmission and processing system includes a control cable and a control processing system. One end of the control cable is connected to the endoscope module, and the other end passes through the target pipe and is connected to the control processing system. The control processing system analyzes the impurity characteristics of the image transmitted by the integrated optical module in real time based on an algorithm. The system linkage module triggers graded warnings based on the impurity detection results and links the electrolyzer DCS system to form active protection of full-process closed-loop control.

[0007] Furthermore, the target pipeline includes an inlet or outlet pipeline of the electrolytic cell. When in use, the real-time monitoring system can be set on the inlet and / or outlet pipeline of the electrolytic cell.

[0008] Furthermore, the integrated optical module is detachably connected to the mechanical drive module, and the mechanical drive module includes a sleeve portion. The integrated optical module is detachably installed in the sleeve portion. The outer circumference of the sleeve portion is provided with a traveling wheel connected by a swing arm structure. The swing arm structure and the traveling wheel support the sleeve portion in the target pipe. The expansion amplitude of the swing arm structure controls the circumscribed circle trajectory of the traveling wheel to adapt to the diameter of the target pipe.

[0009] Furthermore, the integrated optical module includes a positioning base and a pan / tilt module. The pan / tilt module is provided at one axial end of the positioning base and the other end is connected to a control cable. The pan / tilt module extends out of one end of the sleeve.

[0010] Furthermore, the invention further comprises a pipe interface structure, which comprises an equipment compartment pipe with a flange opening at one end, wherein the space in the equipment compartment pipe is at least sufficient to accommodate the endoscope module; the control cable passes through the equipment compartment pipe and is sealedly connected thereto; The target pipeline is provided with a pipeline flange that matches the flange opening. The pipeline flange includes a flange interface that is pre-set or formed by a pressure-opening hole on the target pipeline.

[0011] Furthermore, a multi-stage sealing structure is provided at the place where the control cable passes through the equipment warehouse pipeline; the multi-stage sealing structure includes an inner seal, an outer seal, and an intermediate seal. The inner seal is arranged on the side of the pipeline interface structure in contact with the material, the outer seal is arranged on the outside of the pipeline interface structure in contact with the normal pressure, and the intermediate seal is arranged between the inner seal and the outer seal.

[0012] Furthermore, the sealed connection is provided with a magnetic fluid sealing structure, including an annular sealing chamber, magnetic fluid, and an electromagnetic coil. The annular sealing chamber is a hollow sealing ring structure in the shape of a circular ring. The hollow interior of the annular sealing chamber is filled with magnetic fluid, and an electromagnetic coil is arranged on the periphery of the annular sealing chamber; the current of the electromagnetic coil is controlled to change the magnetic field strength, thereby adjusting the sealing strength of the annular sealing chamber to the control cable.

[0013] Furthermore, the pan / tilt module integrates a multi-spectral LED light source and a corrosion-resistant endoscope probe, the integrated optical module and the mechanical drive module housing are made of Hastelloy C276, and the lens window of the integrated optical module uses a sapphire protective lens.

[0014] Furthermore, the inner wall of the shell structure made of Hastelloy C276 is integrated with a cooling channel, and circulating cooling water flows through the cooling channel.

[0015] A control method for an endoscope-based electrolytic cell pipeline impurity real-time detection system includes the aforementioned electrolytic cell pipeline impurity real-time detection system; the method comprises the following steps: S1: Build the overall system architecture, including the construction of a corrosion-resistant and high-pressure resistant online detection system to achieve online monitoring, visualization, and intelligent analysis of pipeline impurities; Installation of the pipeline interface structure: Install the pipeline interface structure with the built-in endoscope module on the flange interface of the target pipeline, start the magnetic fluid sealing structure, and dynamically adjust the magnetic field strength through the PID controller linked to the pressure sensor; S2: Open the isolation valve to connect the pipeline interface structure with the target pipeline, and the endoscope module moves from the pipeline interface structure into the target pipeline; S3: Impurity detection and analysis process: The endoscope module enters the target pipeline, the mechanical drive module controls the axial movement of the probe, the pan / tilt module controls the probe's rotational detection, and a multi-spectral LED light source provides fractional illumination to obtain high-definition images of the pipeline's inner wall. The optical fiber imaging bundle transmits the image in real time to the control and processing system, which performs AI analysis. The deep learning model installed in the analysis unit identifies the size, location, and type of impurities. S4: Closed-loop control and impurity handling, triggering different levels of alarms based on impurity size: Level I risk, control actions: immediately trigger the audible and visual alarm; link the electrolyzer DCS system: cut off the anode / cathode power supply; close the pneumatic ball valves upstream and downstream of the detection point to isolate the faulty pipeline; Level II risk, control actions: The yellow warning light flashes, and a heat map of the impurity location pops up in the central control room; the pipeline filter and self-cleaning system are activated: the material is filtered through multiple stages to remove impurities; Level III risk, control actions: The blue status light is always on, an impurity distribution trend curve is generated on the operation interface; the detection frequency is automatically adjusted.

[0016] The advantages and beneficial effects of the present invention are: 1. Extreme environmental adaptability and long-term reliability: The system utilizes a Hastelloy C276 housing, sapphire protective lenses, and a gradient composite coating, combined with a cooling channel design. This allows the system to operate stably in high-temperature, high-pressure, and highly corrosive environments. The probe has a continuous operating life of ≥80,000 hours, more than five times that of traditional endoscopes. The magnetic fluid dynamic seal structure, through a double-layer sealing chamber linked to the electromagnetic coil, achieves dynamic sealing for cable entry and exit in high-pressure environments, solving a key engineering challenge for online inspection.

[0017] 2. High-precision detection and intelligent analysis capabilities. This system integrates a multispectral LED light source (400-1000nm) with a fiber optic imaging bundle, and works with an improved YOLOv7 deep learning model to identify particles as small as 0.2mm. This technology boasts a fivefold increase in detection sensitivity compared to traditional technologies, achieving an accuracy rate of ≥98%. Multispectral imaging enables visual identification of impurity shape and location.

[0018] 3. Full-process closed-loop control and active safety protection, a three-level impurity classification warning mechanism (Level I emergency shutdown, Level II flow rate regulation, Level III trend monitoring) is established, and it is linked with the electrolyzer DCS system in real time. The emergency response can automatically cut off the power supply, close the valve and start nitrogen purge to avoid serious accidents such as plate burning. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural diagram of embodiment 1 of the present invention; Figure 2 This is one of the structural diagrams of the second embodiment of the present invention; Figure 3 This is the second structural diagram of the second embodiment of the present invention Figure 4 It is a structural schematic diagram of the multi-stage sealing structure of the present invention; Figure 5 is a structural diagram of embodiment 3 of the present invention; Figure 6 It is a structural schematic diagram of the endoscope module in the present invention; Figure 7 is an exploded view of the endoscope module of the present invention; Figure 8 It is a module connection diagram of the present invention; Figure: 1. Endoscope module; 2. Integrated optical module; 3. Mechanical drive module; 4. Control cable; 5. Control processing system; 6. Sleeve; 7. Swing arm structure; 8. Travel wheel; 9. Positioning base; 10. PTZ module; 11. Pipe interface structure; 12. Flange opening; 13. Equipment compartment pipeline; 14. Target pipeline; 15. Pipe flange; 16. Multi-stage sealing structure; 17. Inner seal; 18. Outer seal; 19. Intermediate seal; 20. Magnetic fluid Sealing structure; 21. Annular sealing chamber; 22. Magnetic fluid; 23. Electromagnetic coil; 24. Isolation valve; 25. Fixed seal; 26. Rewinding device; 27. Rewinding frame; 28. Rewinding motor; 29. ​​Lip seal; 30. Sealing chamber; 31. Purge air source; 32. Drain pipe; 33. Lip; 34. Self-tightening coil spring; 35. Step; 36. Hard material; 37. Capillary; 38. Automatic rehydration module; 39. Swing arm; 40. Axial moving ring. DETAILED DESCRIPTION

[0020] The following embodiments are further described in conjunction with the accompanying drawings and examples. The following embodiments are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0021] Example 1: A real-time detection system for impurities in an electrolytic cell pipeline based on an endoscope comprises an endoscope module 1 that is controlled to move in the pipeline, a pattern transmission and processing system, and a system linkage module. The real-time detection system in this embodiment is a detection device fixedly installed on the target pipeline of the electrolytic cell. For example, the detection system is installed in the alkali solution pipeline connecting the electrolytic cell and the separation system, where impurities are most likely to remain during the construction process. Specifically, Figure 1 As shown, a tee structure can be designed at the elbow of the target pipe 14, a pipe flange 15 is set at one end of the horizontal branch of the tee, and a pipe interface structure 11 is installed on the pipe flange 15. The pipe interface structure 11 includes an equipment bin pipe 13 with a flange opening 12 at one end, and the space inside the equipment bin pipe 13 is at least sufficient to accommodate the endoscope module 1; the control cable 4 passes through the equipment bin pipe 13 and is sealed and connected to it.

[0022] The endoscope module 1 comprises an integrated optical module 2 and a mechanical drive module 3. The mechanical drive module 3 acts as the power source for the endoscope module 1, controlling its movement within the target pipe 14 and visually capturing impurities within the pipe. The integrated optical module 2 is equipped with a multi-spectral LED light source with a wavelength range of 400-1000 nm, supporting both visible and near-infrared imaging. The probe housing is made of Hastelloy C276, offering a pressure resistance of 10 MPa and a temperature resistance of 150°C. Visible and infrared imaging features multiple switching modes, such as 400-700 nm visible light and 700-1000 nm near-infrared light. Using different wavelengths enhances the contrast of specific impurities. For example, metal shavings have more pronounced reflective properties under near-infrared light, while polymer particles show more distinct color differences under visible light. The lens window of the integrated optical module 2 utilizes a 2 mm thick sapphire protective lens that is resistant to acid and alkali corrosion. The sapphire lens has a transmittance of ≥90% (visible light band) and a refractive index of 1.76-1.77, reducing image distortion caused by light refraction and improving image clarity.

[0023] The pattern transmission and processing system includes a control cable 4 and a control processing system 5. The control cable 4 includes a signal cable and an optical fiber imaging bundle. During specific implementation, one end of the control cable 4 is connected to the endoscope module 1, and the other end is connected to the control processing system 5. The signal cable can be connected to the mechanical drive module 3 to drive the movement of the endoscope module in the pipeline, and the optical fiber imaging bundle is used to transmit the image data collected by the integrated optical module 2; the control processing system 5 analyzes the impurity characteristics of the image transmitted by the optical fiber imaging bundle in real time based on the algorithm; one end of the endoscope module 1 transmits the collected monitoring data to the external processing center through the control cable 4, and analyzes and processes the data. The control processing system 5 is outside the target pipeline 14 and is connected to the internal endoscope module 1 through the control cable 4; since the endoscope module 1 needs to move a certain distance in the target pipeline 14, a reeling device 26 for the control cable 4 can be set in the equipment warehouse pipeline 13 to support the movement of the endoscope module 1 within the range of the target pipeline 14. The reeling device 26 includes a reeling frame 27 rotatably connected to the equipment bin pipeline 13 and a reeling motor 28 driving the reeling frame 27 to rotate.

[0024] Since the real-time detection system is fixed, the structure where the control cable 4 passes through the equipment bin pipe 13 can be designed as a fixed seal 25. For example, the position where the control cable 4 passes through the equipment bin pipe 13 is fixed and will not move or rotate axially, that is, the metal shell of the control cable 4 can be welded and fixed to the equipment bin pipe 13, and a winding device for winding the flexible control cable 4 is set in the equipment bin pipe 13. The rotating shaft of the winding device can be controlled by a motor to perform winding and unwinding operations. The rotating shaft can be sealed with a valve stem sealing structure similar to a valve at the place where the rotating shaft passes through the equipment bin pipe 13; and the speed at which the winding device rewinds and unwinds the control cable 4 is coordinated with the moving speed of the endoscope module 1, so that it can move freely in the target pipe 14, and there will be no risk of accumulation and entanglement of the control cable 4; therefore, the equipment bin pipe 13 of this embodiment must have sufficient volume to accommodate the endoscope module 1 and the winding device 26.

[0025] The endoscope module 1 moves in the target pipe 14 to monitor the situation in the target pipe 14 in real time, and generates data to be transmitted through the control cable 4. The detected impurities are analyzed by the AI ​​analysis unit. The AI ​​analysis unit is equipped with a deep learning model (an improved version of YOLOv7). The training data set contains 10 types of impurity features such as metal chips, polymer particles, and bubbles. Therefore, the volume, type and other data of the impurities monitored by the endoscope can be identified, and the identification accuracy rate is ≥98%.

[0026] The system linkage module triggers graded warnings based on impurity detection results, interfacing with the electrolytic cell's DCS control system to enable the electrolytic cell system to respond to the warnings. The system linkage module provides graded warnings for different impurity types, triggering corresponding alarms based on impurity size, thereby alerting process personnel to risks. This embodiment enables in-situ, real-time, visual inspection of the pipeline interior without requiring large-scale disassembly of the pipeline, and can identify and locate unidentified impurities, thereby ensuring the safe and stable operation of the electrolytic cell.

[0027] Specifically, a control method for an endoscope-based electrolytic cell pipeline impurity real-time detection system includes the aforementioned electrolytic cell pipeline impurity real-time detection system; and includes the following steps: S1: Build the overall system architecture, including the construction of a corrosion-resistant and high-pressure resistant online detection system to achieve online monitoring, visualization, and intelligent analysis of pipeline impurities; Corrosion-Resistant Endoscope Assembly: Probe Manufacturing: The outer shell is made of Hastelloy C276, and the cylindrical probe is formed through Metal Injection Molding (MIM). Internally, the optical module integrates: a sapphire protective lens (2mm thick) and a multi-spectral LED light source (400-1000nm), with a corrosion-resistant anti-reflection coating on the lens surface. Drive Module: A micro-stepping motor (accuracy of ±0.1mm) drives the probe's 360° rotation and axial movement, suitable for pipelines larger than DN20. Corrosion-resistant treatment: The probe surface is sprayed with a gradient composite layer of diamond-like carbon coating (DLC), nickel-phosphorus alloy, and Hastelloy, with a corrosion resistance life of ≥80,000 hours (in 30% KOH solution).

[0028] Furthermore, a cooling channel may be integrated into the inner wall of the shell structure made of Hastelloy C276, and circulating cooling water flows through the cooling channel, thereby ensuring that the endoscope module 1 always operates at a suitable temperature.

[0029] S2: Open the isolation valve 24 (optional) to connect the pipeline interface structure 11 with the target pipeline 14, and the endoscope module 1 moves from the pipeline interface structure 11 into the target pipeline 14; Endoscopic scanning: The probe moves into the pipeline, and the drive module controls axial movement (speed ≤ 10 mm / s) and 360° rotation of the probe. A multi-spectral light source (blue, green, red, and near-infrared) illuminates the pipeline in a time-sharing manner, capturing high-definition images of the pipeline interior. A fiber-optic imaging bundle transmits these images in real time to the AI ​​analysis unit, which simultaneously triggers the optional Raman spectroscopy module to collect impurity composition data (500-2000 cm⁻¹ spectrum).

[0030] S3: Impurity detection and analysis process: The endoscope module 1 enters the target pipe 14, the mechanical drive module 3 controls the axial movement of the probe, the pan / tilt module 10 controls the rotational detection of the probe, and the multi-spectral LED light source provides fractional illumination to obtain a high-definition image of the pipe inner wall. The optical fiber imaging bundle transmits the image in real time to the control processing system 5, which performs AI analysis. Image transmission and processing system deployment: Fiber optic link: Utilizes a 60,000-core multimode fiber bundle, resistant to electromagnetic interference, with a transmission distance of ≤50m and a resolution of ≥500×500 pixels. AI analysis unit: Equipped with an improved version of the YOLOv7 algorithm, trained on a dataset containing 10 types of impurities (such as metal shavings and polymers), with a recognition accuracy of ≥98% and image processing latency of ≤0.5 seconds.

[0031] The deep learning model on the analysis unit identifies impurity size, location, and type. The YOLOv7 algorithm identifies impurity size, location, and type (such as metal shavings and welding slag) and combines it with Raman spectroscopy data to verify the material (with an accuracy of ≥95%). A model of impurity migration dynamics is established, and particle trajectories are tracked using optical flow to predict blockage risks (with an accuracy of ≥95%).

[0032] S4: Closed-loop control and impurity handling, triggering different levels of alarms based on impurity size: Level I risk, control actions: immediately trigger the audible and visual alarm; link the electrolyzer DCS system: cut off the anode / cathode power supply; close the pneumatic ball valves upstream and downstream of the detection point to isolate the faulty pipeline; Level II risk, control actions: The yellow warning light flashes, and a heat map of the impurity location pops up in the central control room; the pipeline filter and self-cleaning system are activated: the material is filtered through multiple stages to remove impurities; Level III risk, control actions: The blue status light is always on, an impurity distribution trend curve is generated on the operation interface; the detection frequency is automatically adjusted.

[0033] Example 2: In the aforementioned embodiment, the real-time detection system is fixedly installed on the target pipeline of the electrolyzer. Its advantage is that the control cable 4 is easier to seal when passing through the equipment warehouse pipeline 13. However, it also has certain defects, that is, the internal space of the equipment warehouse pipeline 13 must be large enough to accommodate a certain length of control cable 4. The length of the control cable 4 determines the length that the endoscope module 1 can travel, which also limits the range of movement of the endoscope. At the same time, the equipment warehouse pipeline 13 in Example 1 is too large and occupies a lot of space. It is difficult to set it between chemical pipelines with narrow space, and it is not convenient to improve and upgrade the pipelines of the old electrolyzer hydrogen production system. Therefore, this embodiment improves this and forms a real-time detection system that is easy to improve and upgrade the target pipeline 14, occupies less space, and is easy to install and disassemble.

[0034] In actual use, the pressure tapping operation can be performed on the target pipeline 14, and the pipeline flange 15 for connecting the pipeline interface structure 11 can be welded. The pressure tapping function can be selected on the straight pipe section or at the elbow, such as Figure 2 、 3 As shown, an isolation valve 24 is installed on the pipe flange 15. When no inspection is performed normally, a blind plate can be installed at the isolation valve 24. If it is necessary to perform online real-time monitoring of a target pipeline 14 at a certain location, the blind plate can be removed and the pipeline interface structure 11 can be connected to the flange of the isolation valve 24. Another advantage of this embodiment is that only a small number of real-time monitoring systems need to be set up to perform online inspections on many target pipelines 14, thereby greatly reducing the equipment cost. In actual use, the two embodiments can be selected for installation according to user needs.

[0035] Specifically, the control cable 4 passes through the equipment bin pipe 13 and forms a sliding sealing connection therewith. The sliding sealing connection is not limited to axial sliding, and the control cable 4 also maintains a good sealing effect when rotating circumferentially.

[0036] A multi-stage sealing structure 16 is provided at the place where the control cable 4 passes through the equipment warehouse pipe 13; the multi-stage sealing structure 16 includes an inner seal 17, an outer seal 18, and an intermediate seal 19. The inner seal 17 is arranged on the side of the pipe interface structure 11 in contact with the material, the outer seal 18 is arranged on the outside of the pipe interface structure 11 in contact with the normal pressure, and the intermediate seal 19 is arranged between the inner seal 17 and the outer seal 18. In actual use, both the inner seal 17 and the outer seal 18 can adopt a structural design with multiple lip seals 29, and the lip petals 33 of the inner seal 17 and the outer seal 18 extend in the same direction; the intermediate seal 19 in this embodiment can adopt a normal pressure seal or a pressurized seal; specifically, during normal pressure sealing, a sealed chamber 30 is formed between the outer seal 18 and the inner seal 17, the upper end of the sealed chamber 30 is connected to the purge gas source 31, and the lower end is connected to the drain pipe 32; the inner side of the inner seal 17 is in contact with the material, and under the pressure of the material, the lip petals 33 of the lip seal 29 are pressed and sealed on the control cable 4 to form a seal; Figure 4 As shown, in this embodiment, a multi-ring lip sealing ring 29 is used, the inner ring of the lip 33 of the sealing ring is attached to the control cable 4, and the outer ring of the lip 33 is applied with an elastic clamping force by the self-tightening coil spring 34. The lip 33 of the lip sealing ring 29 provided in the inner sealing layer 17 is arranged toward the material side, and the lip 33 can be pressed against the control cable 4 by the pressure of the material itself, forming a seal under the dual pressure of the material pressure and the elastic clamping force, and because of the multi-layer arrangement, the sealing effect is improved while ensuring a smaller leakage rate.

[0037] However, since this embodiment requires the control cable 4 to enter and exit the equipment warehouse pipe 13 so that the endoscope module 1 can move freely, a better sealing effect can be maintained when the cable is fixed. When the control cable 4 is pulled in and out, a part of the material will pass through the inner seal 17 and enter the middle seal 19. At this time, the leaked material is discharged from the drain pipe 32 and sent to the collection tank by normal pressure purge, and the outer seal 18 also uses the lip 33 to seal the control cable 4. The outer seal 18 is mainly used to seal a small amount of material leaked into the chamber of the middle seal 19 to prevent it from leaking out. When the material enters the sealed chamber 30 of the middle seal 19, the pressure is naturally reduced, so the outer seal 18 does not need to bear a large sealing pressure; the leaked part of the material is automatically discharged from the drain pipe 32 under normal pressure purge.

[0038] Since the volume of the entire device is reduced in this embodiment, it can be installed in a relatively small pipe space. It can be understood that in this embodiment, the endoscope module 1 and the imaging principle are the same as those in the first embodiment; however, when the endoscope module 1 moves in the pipe, it is necessary to apply auxiliary power to the control cable 4 on the outside of the multi-stage sealing structure 16 end to assist the control cable 4 in pulling in and out of the multi-stage sealing structure 16 so that the endoscope module 1 can move freely in the pipe.

[0039] This embodiment differs from the previous embodiment in that, due to the need to miniaturize the entire device, the space occupied by the device chamber conduit 13 in the first embodiment needs to be minimized. Therefore, in this embodiment, the space within the device chamber conduit 13 is required to at least accommodate the endoscope module 1. Since the endoscope module 1 is generally in the shape of an elongated cylinder, the diameter of the device chamber conduit 13 can be comparable to or even smaller than the target conduit 14, and there is no need to provide space for the reeling device 26 with a larger radius. This brings about the problem of sealing the control cable 4 through the wall of the device chamber conduit 13.

[0040] Example 3: As an improvement to Example 2, a magnetic fluid 22 sealing structure 20 is provided at the sealing connection to meet the purpose of sliding sealing of the control cable 4. The magnetic fluid 22 sealing structure 20 in this embodiment can be set in the inner layer seal 17 and / or the outer layer seal 18 as needed, and the number of settings in each sealing layer is not limited.

[0041] Specifically, the magnetic fluid 22 sealing structure 20 includes an annular sealing chamber 21, magnetic fluid 22, and an electromagnetic coil 23. The annular sealing chamber 21 is a hollow, ring-shaped sealing ring structure. The hollow interior of the annular sealing chamber 21 is filled with magnetic fluid 22. A stepped 35-degree annular chamber design can be used. Its inner diameter matches the diameter of the control cable 4, with a tolerance of +0.05mm. For example, the axial length is 15mm, and the chamber wall thickness is 1.5mm. The chamber is filled with magnetic fluid 22, specifically: nano-Fe3O4 colloid with a particle size of 10nm, a concentration of 30vol%, a perfluoropolyether base liquid, and a fluorocarbon surfactant. The viscosity is 500cP, the density is 1.8g / cm³, and it has a stable dispersion for ≥1 year in an environment with a pH of 0-14. The filling volume is 80-90% of the chamber volume, with 10-20% space reserved to accommodate volume changes during cable entry and exit.

[0042] like Figure 5As shown, the step 35-type design of the annular sealing chamber 21 can be a vertical wall on one side and a step 35 wall on the other side; in actual use, a composite step 35-type sealing chamber can be formed by using a deformable flexible material plus a hard material 36 with relatively high hardness, so that the step 35 has a certain deformation performance, and a hard material 36 is set in the vertical wall and in the vertical step 35 of the step 35, so that when the step 35 side is deformed, the horizontal step 35 that was originally not in contact with the control cable 4 moves radially toward the center along the control cable 4 after deformation, thereby The contact area between the annular sealing cavity 21 and the control cable 4 is increased to further improve the sealing effect; it is understandable that its deformation can be achieved by replenishing the magnetic fluid 22 into the interior; specifically, a magnetic fluid 22 supply system can be added to the annular sealing cavity 21, and an automatic liquid replenishment module 38 is set on the outside, and is connected to the interior of the annular sealing cavity 21 through a capillary 37. After the equipment is installed and before the isolation valve 24 is opened, the supply amount of the magnetic fluid 22 is appropriately increased or decreased according to the pressure in the target pipeline 14, so that it can easily enter and exit the annular sealing cavity 21 when it is liquid.

[0043] The electromagnetic coil 23 is a toroidal spiral coil using a winding structure. The conductor material is Φ0.1mm nickel-chromium alloy enameled wire (corrosion-resistant, temperature-resistant to 200°C), with a polyimide insulation layer. Its DC resistance is approximately 50Ω. The electromagnetic coil 23 is sheathed around the outer circumference of the annular sealed cavity 21. Its axial length is proportional to the number of annular sealed cavities 21 provided. For example, if three annular sealed cavities 21 are provided at the inner seal 17, and the axial length is 15mm, then the axial length of the electromagnetic coil 23 must be no less than 45mm. To account for the spacing between the three annular sealed cavities 21, the axial length of the electromagnetic coil 23 may need to be increased accordingly. Alternatively, a one-to-one design of annular sealed cavities 21 and electromagnetic coil 23 may be employed.

[0044] The design principle of this embodiment is based on the regulation of the magnetic field on the magnetic fluid 22. The magnetic field strength is controlled by the current, which realizes the dynamic regulation of the sealing performance of the magnetic fluid 22, thereby forming a dynamic seal. The magnetic field strength can be changed by adjusting the current, thereby controlling the sealing performance of the magnetic fluid 22. When there is no magnetic field, the magnetic fluid 22 is in a liquid state and can flow freely, allowing the cable to enter and exit easily. When the electromagnetic coil 23 is energized to generate a magnetic field, the magnetic particles are oriented and arranged in the magnetic field, forming a "chain structure", which causes the viscosity of the magnetic fluid 22 to increase sharply, and it becomes semi-solid. It fills the gap between the cable and the sealing cavity, forming a liquid sealing ring, preventing the leakage of high-pressure materials in the pipeline. By adjusting the reasonable current size, the control cable 4 can enter and exit and the amount of material leaking into the intermediate seal 19 is minimized.

[0045] Furthermore, in this embodiment, the electromagnetic coil 23, a pressure sensor, and a PID controller form a closed-loop control system. The pressure sensor is installed on the target pipeline 14 and monitors the pressure within the pipeline in real time. When the pressure is high, the PID controller automatically increases the coil current, enhancing the magnetic field strength, and synchronously increases the sealing pressure of the magnetic fluid 22, offsetting the pressure increase within the pipeline and preventing material leakage. When the pressure is low, the coil current decreases, and the magnetic fluid 22 returns to a low-viscosity state, reducing the resistance to cable movement and achieving pressure-adaptive sealing. Preferably, the electromagnetic coil 23 uses a toroidal spiral winding and is combined with a conical magnetic pole shoe to guide the magnetic field, forming a strong magnetic field gradient at the sealing gap. The gradient value can reach 500kA / m², ensuring that the magnetic fluid 22 forms a uniform and stable sealing layer in the radial direction (radius of the cable), avoiding the risk of leakage caused by uneven magnetic field distribution.

[0046] Initially, magnetic fluid 22 is injected into the stepped 35-shaped annular cavity, filling it to 80% to ensure that the liquid is evenly distributed between the cable and the cavity, with a gap of 0.1-0.3mm. The cable can enter and exit at low speeds. During dynamic seal control, a pressure sensor monitors the pipeline pressure in real time with an accuracy of 0.1% FS. As pressure rises, a PID controller automatically increases the current in the electromagnetic coil 23, strengthening the magnetic field. The magnetic fluid 22 compresses the cable radially, forming a "liquid sealing ring" with a pressure resistance of ≥10 MPa.

[0047] In this embodiment, the debugging and experiments of the system include: sealing performance test, corrosion resistance test, and detection accuracy verification.

[0048] The sealing performance test involves applying 10MPa water pressure in the simulated pipeline for 24 hours and monitoring the leakage rate to be less than 10⁻ 9 Pa・m³ / s; when the cable moves axially (5mm / s) and rotates (100rpm), the leakage rate is less than 10⁻ 9 Pa・m³ / s.

[0049] The corrosion resistance test involves immersing the probe in a 30% KOH solution for 8,000 hours of continuous operation, with the coating weight loss rate being less than 0.01% and the optical transmittance drop being less than 3%.

[0050] Verification of detection accuracy includes placing 0.2mm metal chips in a simulated pipeline, with a system recognition rate of ≥98%; in a multi-impurity mixed scenario, the detection speed is ≥25fps, and the anti-bubble interference rate is ≥95%.

[0051] Example 4: As an improvement, the integrated optical module 2 and the mechanical drive module 3 are connected in a detachable manner. Figure 6 、 7As shown, the endoscope module 1 can be adapted to target pipes 14 of various diameters. Only the mechanical drive module 3 needs to be replaced, while the integrated optical module 2 does not need to be replaced, further reducing the equipment procurement cost.

[0052] Specifically, the mechanical drive module 3 includes a sleeve portion 6, and the integrated optical module 2 is detachably mounted within the sleeve portion 6. The outer circumference of the sleeve portion 6 is provided with a travel wheel 8 connected by a swing arm structure 7. The swing arm structure 7 and the travel wheel 8 support the sleeve portion 6 in the target pipe 14. The expansion range of the swing arm structure 7 controls the circumscribed circular trajectory of the travel wheel 8 to adapt to the diameter of the target pipe 14. The swing arm structure 7 designed in this embodiment is based on a scissor-type structure. Two swing arm rods 39 are hinged at the middle, one swing arm rod 39 end is hinged to the sleeve portion 6, and the other swing arm rod 39 is hinged to the axial movable ring 40. The axial movable ring 40 can be externally controlled to move its position and adaptively adjust the pipe diameter. The other end of the swing arm rod 39 is a power-driven travel wheel 8. Therefore, through the movement of the axial movable ring 40, the deformation of multiple sets of surrounding swing arm structures 7 is simultaneously changed, thereby being applicable to pipes of various diameters within a certain range.

[0053] Furthermore, the integrated optical module 2 includes a positioning base 9 and a pan / tilt module 10. The pan / tilt module 10 is disposed at one axial end of the positioning base 9 and connected to the control cable 4 at the other end. The pan / tilt module 10 extends from one end of the sleeve portion 6. The positioning base 9 is fixed within the sleeve portion 6, and the pan / tilt module 10 can monitor the interior of the target pipe 14 by rotating.

[0054] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. A real-time detection system for impurities in electrolytic cell pipelines based on endoscope, characterized in that: It includes an endoscope module, a pattern transmission and processing system, and a system linkage module; the endoscope module is controlled to move in the target pipe; The endoscope module includes an integrated optical module and a mechanical drive module, which moves in the pipeline and visually collects impurities in the pipeline; The pattern transmission and processing system includes a control cable and a control processing system. One end of the control cable is connected to the endoscope module, and the other end passes through the target pipe and is connected to the control processing system. The control processing system analyzes impurity characteristics of the image transmitted by the integrated optical module based on an algorithm; The system linkage module triggers a graded warning based on the impurity detection results and links the electrolyzer DCS system.

2. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 1 is characterized in that: The integrated optical module is detachably connected to the mechanical drive module. The mechanical drive module includes a sleeve portion, and the integrated optical module is detachably installed in the sleeve portion. The outer circumference of the sleeve portion is provided with a traveling wheel connected by a swing arm structure. The swing arm structure and the traveling wheel support the sleeve portion in the target pipe. The expansion amplitude of the swing arm structure controls the circumscribed circle trajectory of the traveling wheel to adapt to the diameter of the target pipe.

3. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 2 is characterized in that: The integrated optical module includes a positioning base and a pan / tilt module. The pan / tilt module is arranged at one axial end of the positioning base and the other end is connected to a control cable. The pan / tilt module extends out of one end of the sleeve.

4. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 1 is characterized in that: It also includes an equipment bin pipe with a flange opening at one end, wherein the space in the equipment bin pipe is at least sufficient to accommodate the endoscope module; a control cable passes through the equipment bin pipe and is sealedly connected thereto; The target pipeline is provided with a pipeline flange that matches the flange opening. The pipeline flange includes a flange interface that is pre-set or formed by a pressure-opening hole on the target pipeline.

5. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 4 is characterized in that: A multi-stage sealing structure is provided at the place where the control cable passes through the equipment warehouse pipeline; the multi-stage sealing structure includes an inner seal, an outer seal, and an intermediate seal. The inner seal is arranged on the side of the pipeline interface structure in contact with the material, the outer seal is arranged on the outside of the pipeline interface structure in contact with the normal pressure, and the intermediate seal is arranged between the inner seal and the outer seal.

6. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 4 is characterized in that: The sealed connection is provided with a magnetic fluid sealing structure, including an annular sealing chamber, magnetic fluid, and an electromagnetic coil. The annular sealing chamber is a hollow sealing ring structure in the shape of a circular ring. The hollow interior of the annular sealing chamber is filled with magnetic fluid, and an electromagnetic coil is arranged on the periphery of the annular sealing chamber; the current of the electromagnetic coil is controlled to change the magnetic field strength, thereby adjusting the sealing strength of the annular sealing chamber to the control cable.

7. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 3 is characterized in that: The pan / tilt module is integrated with a multi-spectral LED light source and a corrosion-resistant endoscope probe. The housings of the integrated optical module and the mechanical drive module are made of Hastelloy C276, and the lens window of the integrated optical module is protected by a sapphire lens.

8. The real-time detection system for impurities in electrolytic cell pipelines based on endoscope according to claim 7 is characterized in that: The inner wall of the shell structure made of Hastelloy C276 is integrated with cooling channels, and circulating cooling water flows through the cooling channels.

9. A control method for an endoscope-based electrolytic cell pipeline impurity real-time detection system, characterized in that: The electrolytic cell pipeline impurity real-time detection system according to claim 1 comprises the following steps: S1: Build the overall system architecture, including the construction of a corrosion-resistant and high-pressure resistant online detection system to achieve online monitoring, visualization, and intelligent analysis of pipeline impurities; Installation of the pipeline interface structure: Install the pipeline interface structure with the built-in endoscope module on the flange interface of the target pipeline, start the magnetic fluid sealing structure, and dynamically adjust the magnetic field strength through the PID controller linked to the pressure sensor; S2: Open the isolation valve to connect the pipeline interface structure with the target pipeline, and the endoscope module moves from the pipeline interface structure into the target pipeline; S3: Impurity detection and analysis process: The endoscope module enters the target pipeline, the mechanical drive module controls the axial movement of the probe, the pan / tilt module controls the probe's rotational detection, and a multi-spectral LED light source provides fractional illumination to obtain high-definition images of the pipeline's inner wall. The optical fiber imaging bundle transmits the image in real time to the control and processing system, which performs AI analysis. The deep learning model installed in the analysis unit identifies the size, location, and type of impurities. S4: Closed-loop control and impurity handling, triggering different levels of alarms based on impurity size: Level I risk, control actions: immediately trigger the audible and visual alarm; link the electrolyzer DCS system: cut off the anode / cathode power supply; close the pneumatic ball valves upstream and downstream of the detection point to isolate the faulty pipeline; Level II risk, control actions: The yellow warning light flashes, and a heat map of the impurity location pops up in the central control room; the pipeline filter and self-cleaning system are activated: the material is filtered through multiple stages to remove impurities; Level III risk, control actions: The blue status light is always on, an impurity distribution trend curve is generated on the operation interface; the detection frequency is automatically adjusted.

10. An application of an endoscope-based real-time detection system for impurities in electrolytic cell pipelines, characterized in that: It comprises the real-time detection system according to claim 1, and the real-time detection system is applied to the liquid inlet and / or liquid outlet pipelines of the electrolytic cell.

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