Boiler expansion indication three-dimensional remote transmission measurement method, system, equipment and medium

Abstract

The invention discloses a boiler expansion indication three-dimensional remote transmission measurement method, system and equipment and a medium, and belongs to the technical field of boiler monitoring, and the method comprises the steps: obtaining the real-time distance data of a to-be-measured part of a boiler in a first direction, a second direction and a third direction through a measurement device disposed on the to-be-measured part of the boiler; according to the real-time distance data and preset reference distance data when the boiler does not expand, the expansion amount of the boiler component to be measured in the first direction, the second direction and the third direction is determined; converting the swelling amounts in the first direction, the second direction and the third direction into standard signals; and sending the standard signal to a monitoring system for display. According to the invention, high-precision three-dimensional measurement, automatic data remote transmission and intelligent analysis and early warning based on data are realized, so that the measurement precision and reliability are improved, automatic monitoring and graded early warning are realized, and intelligent diagnosis can be carried out to distinguish real abnormity and measurement interference.

Description

Technical Field

[0001] This invention relates to the field of energy storage equipment technology for power systems, specifically to a three-dimensional remote measurement method, system, equipment, and medium for boiler expansion indication. Background Technology

[0002] Boilers in large thermal power plants are the core hubs of energy conversion. Their complex structures and stringent parameters cause critical pressure-bearing components such as the steam drum, headers, water-cooled walls, and main reheat steam pipelines to experience drastic temperature and pressure changes during start-up, shutdown, and load variations. The thermal expansion and contraction properties of materials cause these components to undergo geometric displacement under different operating conditions—a process known as thermal expansion. Accurate and real-time monitoring of this thermal expansion is crucial for ensuring the safe and stable operation of the boiler. By monitoring expansion data, operators can determine whether the boiler and its support system are expanding freely as designed, and promptly detect problems such as obstructed expansion, abnormal deformation, and support failure caused by improper control of the heating and pressurization rate, design or installation defects, or poor post-maintenance recovery. This effectively prevents major safety accidents such as component cracks, leaks, and even pipe ruptures caused by stress concentration, fatigue accumulation, or creep damage. Currently, the industry primarily uses traditional mechanical expansion indicators for monitoring. Its typical structure involves fixing or welding one end of a metal pointer to the expansion component of the boiler to be measured. The pointer usually extends horizontally, while the other end points to a scale plate with coordinates fixed to a relatively static reference point such as the boiler's steel structure or the beams and columns of the plant. The horizontal expansion is read by observing the X-axis (horizontal) and Y-axis (vertical) displacement of the pointer tip on the scale plate; the Z-axis (axial) expansion is obtained by measuring the change in distance between the pointer tip and the scale plate.

[0003] Although mechanical expansion indicators have been used for a long time due to their simple structure and low cost, their inherent limitations are becoming increasingly apparent as modern thermal power units develop towards larger capacity, higher parameters, higher automation, and greater intelligence. They can no longer meet the demands for refined and highly reliable safety monitoring. First, their measurement accuracy and reliability are limited. The contact or close-range indication method between the mechanical pointer and the scale plate is susceptible to mechanical wear, corrosion, jamming, and bending deformation of the pointer due to its own weight or heat, leading to deviations in the measurement readings. Simultaneously, boiler room environments are typically characterized by high temperatures, high dust concentrations, and strong vibrations from equipment operation. These harsh environmental factors severely interfere with the stability of the mechanical structure and the clarity of the readings, further reducing measurement reliability. Second, they suffer from low automation and poor real-time performance. Mechanical indicators require operators to periodically visit the site for manual visual reading and recording. This not only consumes a significant amount of manpower and increases the exposure time of operators in high-risk areas, but more importantly, it cannot achieve continuous, real-time data acquisition. Manual readings inherently involve subjective errors, and the recording and transmission of data can also introduce errors. Furthermore, the time lag in data acquisition prevents monitoring systems from capturing transient changes or rapid anomalies during expansion, hindering early warning and accident tracing. Secondly, measurement dimensions are limited. Most traditional indicators focus on one- or two-dimensional expansion. Even when combined to achieve three-dimensional measurement, the measurements in each direction are independent, making it difficult to accurately reflect complex spatial torsion or composite deformation, and failing to provide complete three-dimensional displacement vector information. Finally, and most critically, there is a lack of data integration and intelligent analysis capabilities. Mechanical indicators are essentially isolated local instruments, unable to convert their measurement results into standard electrical signals for remote transmission, thus preventing seamless integration with the power plant's distributed control system (DCS). This results in valuable expansion data being unable to be recorded, stored, analyzed, and displayed by the DCS. Operators cannot remotely monitor from the central control room, and it is impossible to correlate expansion data with other key operating parameters (such as load, temperature, and pressure), making it difficult to develop data-driven trend prediction, health assessment, and intelligent early warning models. Summary of the Invention

[0004] In view of the above-mentioned problems, the present invention is proposed.

[0005] Therefore, the technical problem solved by this invention is: how to achieve accurate, real-time, three-dimensional automated monitoring of the expansion of key boiler components through non-contact three-dimensional optical measurement and intelligent data processing technology, overcome the limitations of accuracy, dimensionality and reliability of traditional mechanical monitoring, and establish deep integration with the monitoring system to achieve intelligent early warning and fault diagnosis, thereby comprehensively improving the safety margin of boiler operation and the level of intelligent management of power plants.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a three-dimensional remote measurement method for boiler expansion indication, comprising the following steps: acquiring real-time distance data of the boiler component under test in a first direction, a second direction, and a third direction using a measuring device mounted on the boiler component under test; wherein, the measuring device includes a hexahedron connected to the boiler component under test and a fixedly mounted triangular cover, the hexahedron being provided with three infrared measuring sensors respectively facing the first direction, the second direction, and the third direction, and the triangular cover having three reflective surfaces respectively perpendicular to the first direction, the second direction, and the third direction, the first direction, the second direction, and the third direction being mutually perpendicular; determining the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction based on the real-time distance data and preset reference distance data when the boiler is not expanded; converting the expansion amount in the first direction, the second direction, and the third direction into standard signals; and sending the standard signals to a monitoring system for display.

[0007] As a preferred embodiment of the three-dimensional remote measurement method for boiler expansion indication according to the present invention, the step of acquiring real-time distance data of the boiler component under test in a first direction, a second direction, and a third direction using a measuring device disposed on the component under test of the boiler includes: transmitting a measurement signal to three corresponding reflective surfaces of the triangular hood using the infrared measuring sensor, and receiving the echo signal reflected by the reflective surfaces; determining the time difference between the transmission of the measurement signal and the reception of the echo signal; and determining the real-time distance data based on the time difference.

[0008] The beneficial effects of this preferred technical solution are as follows: by explicitly using the time difference between the transmitted measurement signal and the received echo signal to determine the real-time distance data, the measurement principle is concretized. This not only makes the measurement process clearer and more verifiable, and directly links it to physical-level time measurement, but also provides a specific and reliable physical quantity basis for subsequent high-precision distance calculation and signal quality analysis, thereby improving the technical clarity and feasibility of the measurement solution.

[0009] As a preferred embodiment of the three-dimensional remote measurement method for boiler expansion indication according to the present invention, the step of determining the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction based on the real-time distance data and the preset reference distance data when the boiler is not expanded includes: acquiring the reference distance data of the boiler under a preset reference operating condition; comparing the difference between the real-time distance data and the reference distance data to obtain the expansion amount reflecting the displacement change of the boiler component under test.

[0010] As a preferred embodiment of the three-dimensional remote measurement method for boiler expansion indication described in this invention, the step of converting the expansion amounts in the first direction, the second direction, and the third direction into standard signals includes: determining that the standard signals are standard industrial signals; establishing a preset mapping relationship between the expansion amounts and the standard industrial signals; and converting the expansion amounts into the standard industrial signals according to the preset mapping relationship.

[0011] As a preferred embodiment of the three-dimensional remote measurement method for boiler expansion indication described in this invention, the step of sending the standard signal to the monitoring system for display includes: connecting the standard industrial signal to the monitoring system via a data interface; and displaying the expansion amount in the first direction, the second direction, and the third direction in real time on the user interface of the monitoring system in a numerical or graphical manner.

[0012] As a preferred embodiment of the three-dimensional remote measurement method for boiler expansion indication described in this invention, the monitoring system uses the preset mapping relationship to reverse-parse the received standard industrial signal into the expansion amount, and compares the expansion amount with the preset multi-level expansion threshold in real time; when the expansion amount in any direction exceeds the corresponding preset expansion threshold, the monitoring system triggers the corresponding early warning or alarm mechanism, and generates and stores historical expansion trend data in conjunction with the expansion amount.

[0013] The beneficial effects of this preferred technical solution are as follows: By utilizing a preset mapping relationship to analyze the expansion amount and setting multiple thresholds for comparison, automated real-time monitoring and tiered early warning of the boiler's expansion status are achieved. Compared to traditional manual inspection and recording methods, this significantly improves response speed and the timeliness of early warning, enabling the earlier detection of potential risks. Simultaneously, the generation and storage of historical expansion trend data provides intuitive and long-term quantitative evidence for operational analysis, fault tracing, and optimization of operational strategies, thereby enhancing the level of management precision.

[0014] As a preferred embodiment of the three-dimensional remote measurement method for boiler expansion indication described in this invention, when the monitoring system triggers the early warning or alarm mechanism, the monitoring system further calls upon the time difference and, in conjunction with the synchronously acquired key operating parameters of the unit, inputs them into a preset health status assessment model; the health status assessment model analyzes the correlation between the change in the time difference and the change in the expansion amount to identify whether the abnormal expansion amount is caused by the actual deformation of the boiler body or by interference from the measurement environment, thereby outputting the boiler health status assessment result after distinguishing the interference factors.

[0015] The beneficial effects of this preferred technical solution are as follows: By linking and calling upon the underlying "time difference" data and alarm events during early warning, and combining this with model analysis based on unit operating parameters, intelligent diagnostic functions are achieved. Its core advantage lies in its ability to effectively distinguish between actual abnormal expansion of the boiler itself and measurement interference caused by harsh environments such as high temperature, dust, and vibration, thereby reducing the false alarm rate. This not only avoids unnecessary downtime for maintenance, reducing maintenance costs and economic losses, but more importantly, it greatly improves the reliability of the monitoring system and the operators' trust in the early warning information, providing a higher level of technical support for ensuring the safe and stable operation of the unit.

[0016] Another objective of this invention is to provide a three-dimensional remote measurement system for boiler expansion indication.

[0017] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a three-dimensional remote measurement system for boiler expansion indication, comprising: a data acquisition module, used to acquire real-time distance data of the boiler component under test in a first direction, a second direction, and a third direction using a measuring device installed on the boiler component under test; an expansion calculation module, used to determine the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction based on the real-time distance data and preset reference distance data when the boiler is not expanded; a signal conversion module, used to convert the expansion amount in the first direction, the second direction, and the third direction into standard signals; and a monitoring and communication module, used to send the standard signals to a monitoring system for display.

[0018] The present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, characterized in that the processor executes the computer program to implement the steps of the aforementioned three-dimensional remote measurement method for boiler expansion indication.

[0019] The present invention provides a computer-readable storage medium having a computer program stored thereon, characterized in that, when the computer program is executed by a processor, it implements the steps of the aforementioned three-dimensional remote measurement method for boiler expansion indication.

[0020] The beneficial effects of this invention are as follows: First, this invention is an improvement upon the widely used boiler expansion indicator, featuring a simple structure and easy installation, making it widely applicable to power plants that have already installed traditional boiler expansion measurement devices. Second, its core utilizes the infrared ranging principle, achieving non-contact three-dimensional measurement. This not only ensures stable and reliable measurement processes and reduces requirements for harsh working environments such as high temperatures and dust, but also fundamentally solves the problems of easy wear, jamming, low accuracy, and missing dimensions associated with traditional mechanical indicators. Most importantly, this invention achieves standard signal conversion and remote transmission of expansion data. Compared to traditional mechanical pointer devices, this allows operators to monitor the boiler's expansion status in real time from the central control room, greatly improving the real-time performance and accuracy of monitoring, and further enhancing the centralized control operation level of the power plant. Furthermore, the implementation of this method can significantly extend the maintenance-free period and reduce the frequency of manual inspections, thereby lowering maintenance costs and labor expenses, and better ensuring the safe and stable operation of the unit. Ultimately, by integrating precise three-dimensional expansion data into the DCS system, a solid foundation was laid for leveraging the powerful computing capabilities of the DCS to perform logical judgments, develop data models, and conduct in-depth analysis of the unit's health status, in conjunction with parameters such as unit operating status, load levels, and boiler wall temperature. This achieved a leap from simple measurement to intelligent monitoring. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 The above is a flowchart of a three-dimensional remote measurement method for boiler expansion indication provided in one embodiment of the present invention. Detailed Implementation

[0023] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0024] Example 1, referring to Figure 1 This is the first embodiment of the present invention, which provides a three-dimensional remote measurement method for boiler expansion indication, comprising:

[0025] S100: Use a measuring device installed on the boiler component under test to acquire real-time distance data of the boiler component under test in the first direction, the second direction, and the third direction.

[0026] The measuring device includes a hexahedron connected to the component to be measured in the boiler and a fixed triangular cover. The hexahedron is equipped with three infrared measuring sensors facing the first, second, and third directions respectively. The triangular cover has three reflective surfaces that are perpendicular to the first, second, and third directions respectively, and the first, second, and third directions are perpendicular to each other.

[0027] S200: Based on real-time distance data and preset reference distance data when the boiler is not expanded, determine the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction;

[0028] S300: Converts the expansion amounts in the first direction, second direction, and third direction upward into standard signals;

[0029] S400: Sends standard signals to the monitoring system for display.

[0030] It should be noted that, as core equipment, the boiler in a thermal power plant undergoes thermal expansion of critical pressure-bearing components such as the steam drum and headers during ignition, pressurization, and operation. Accurate monitoring of the three-dimensional expansion of these components is crucial for timely detection of equipment deformation caused by improper ignition and pressurization or poor installation and maintenance, preventing cracks and leaks due to uneven expansion, and ensuring unit safety. However, the commonly used mechanical expansion indicators have many drawbacks: their mechanical structure is prone to wear, jamming, and bending, leading to decreased measurement accuracy; manual reading and recording by operators on-site is inefficient and prone to data lag and human error; traditional methods struggle to comprehensively capture lateral, longitudinal, and vertical three-dimensional displacements; and the mechanical structure is susceptible to interference from harsh environments such as high temperatures, dust, and vibration, affecting the reliability and stability of measurements. More importantly, traditional indicators cannot transmit measurement data to the DCS system, making real-time dynamic monitoring, early warning, and correlation analysis with other unit operating parameters difficult.

[0031] Therefore, addressing the issues of low accuracy, heavy reliance on manual labor, lack of dimensional accuracy, and inability to transmit data remotely in traditional boiler expansion monitoring, this embodiment utilizes steps S100-S400. A combination of three mutually perpendicular infrared sensors and a fixed triangular shield enables non-contact synchronous measurement of the displacement of the boiler's components in the X, Y, and Z directions. This method is simple in structure and avoids mechanical wear. Step S200, based on a comparison between real-time and reference distances, accurately calculates the three-dimensional expansion. Crucially, steps S300 and S400 convert these precise expansion measurements into standard signals and transmit them to a monitoring system (such as a DCS), completely transforming the manual inspection process and achieving real-time, remote, and automated monitoring of boiler expansion. This not only improves data accuracy and real-time performance, reduces the workload of operators and the risk of human error, but also lays the foundation for subsequent data analysis, trend judgment, health assessment, and intelligent early warning within the monitoring system, significantly enhancing the centralized control operation level of the power plant and the inherent safety of the unit.

[0032] Example 2, refer to Figure 1 This is the second embodiment of the present invention, which provides a three-dimensional remote measurement method for boiler expansion indication.

[0033] In this embodiment of the invention, step S100, which involves using a measuring device to acquire real-time distance data of the boiler component under test in the first, second, and third directions, specifically includes the following steps A1-A2:

[0034] A1: Using three infrared measurement sensors on a hexahedron, infrared measurement signals are emitted to the three corresponding reflective surfaces of the triangular shield, and the echo signals reflected from the reflective surfaces are received. It should be noted that the hexahedron is securely connected to the boiler component under test (e.g., the support point of the steam drum or the fixed bracket of a critical header) via a sufficiently rigid connecting rod, ensuring that it can accurately and lag-free follow the three-dimensional movement of the component under test. The infrared measurement sensors are preferably industrial-grade sensors with narrow beam angles and high repeatability to reduce stray reflections and the influence of ambient light. For example, each infrared measurement sensor emits infrared laser pulses with a duration of 5 nanoseconds at a frequency of 100 pulses per second. Its internal high-sensitivity photodiode receiving unit is used to capture the attenuated but still identifiable pulse signals reflected from the corresponding reflective surfaces.

[0035] It should be noted that the triangular shield is fixed to a stable reference structure (such as a load-bearing column of the plant or a specially cast concrete foundation) independent of the boiler expansion body via a heavy-duty adjustable bracket with fine-tuning function. During initial installation, a laser collimator is used for precise alignment to ensure that the three reflective surfaces of the triangular shield are strictly perpendicular to the corresponding sensor optical axis, minimizing angular errors. Each infrared measurement sensor is connected to the field instrument power supply and signal junction box via an independent, well-shielded four-core cable. Two cores are used to obtain a stable 24V DC power supply, and the other two cores are used for its initial signal output interface. The signal junction box is typically a field stainless steel or cast aluminum junction box with an IP65 or higher protection rating, containing terminal blocks for connecting sensor cables and, if necessary, surge protectors. The signal cables leading from this junction box (which may be multi-pair shielded cables or bus cables depending on the sensor output interface type) are then connected to subsequent signal transmitters or remote I / O stations of the DCS.

[0036] For example, each infrared measurement sensor emits infrared laser pulses with a duration of 5 nanoseconds at a frequency of 100 times per second. Its internal high-sensitivity photodiode receiving unit is used to capture the attenuated but still identifiable pulse signal returned from the corresponding reflective surface.

[0037] A2: Determine the time difference between the transmission of the measurement signal and the reception of the echo signal; and calculate the real-time distance data based on this time difference and the known signal propagation speed (speed of light).

[0038] It should be noted that this calculation process can be completed within the microprocessor inside the sensor. The sensor outputs the calculated real-time distance data through its initial signal output interface (such as an RS485 digital interface or a 0-10V analog voltage interface).

[0039] For example, the high-speed timing circuit inside the sensor records the moments of the leading edges of the transmitted and received pulses with picosecond-level precision, calculating the flight time Δt. Then, by multiplying the flight time by the speed of light and dividing by two, the straight-line distance from the sensor probe to the reflecting surface is calculated. For instance, if the measured flight time is 10 nanoseconds, the distance is 1.5 meters. These three distance values ​​constitute the three-dimensional real-time distance data at that moment. Specifically, three infrared measurement sensors can be connected via an RS485 bus in a daisy-chain or star configuration, each assigned a unique Modbus slave address. The host computer (such as a signal transmitter or the communication interface of a DCS) acts as the Modbus master, sequentially sending commands to the three sensors to read distance data via polling, and receiving the data messages they return, thus achieving time-division multiplexing of distance data in three directions. The acquisition cycle can be set as needed, for example, completing a full poll of the three sensors once per second.

[0040] In an optional implementation, the measuring sensor in step S100 can also be a laser phase-detection distance sensor. This sensor emits a continuous laser beam modulated at a specific frequency (e.g., 150MHz) and calculates the distance by measuring the phase difference between the emitted and received laser beams. This method typically achieves sub-millimeter-level measurement accuracy over short to medium distances (e.g., 0-50 meters) and has strong resistance to ambient light interference, making it particularly suitable for scenarios requiring precise capture of minute expansion changes. Its output interface can also be an RS485 or industrial Ethernet interface, capable of directly outputting high-precision digital distance values.

[0041] In another optional implementation, considering the potentially high dust levels in the boiler room, the measuring sensor in step S100 can also be a microwave radar ranging sensor, such as a 24GHz or 77GHz millimeter-wave radar. Microwaves have a strong ability to penetrate dust and water vapor; although their spot size may be large, they can provide more stable measurement data under harsh conditions with extremely low visibility. Care should be taken to optimize the installation position and angle to avoid interference and reflection from metal structures. Its output interface is typically an RS485 or CAN bus interface, suitable for data transmission in extremely harsh environments.

[0042] In this embodiment of the invention, step S200, which involves determining the expansion amount based on real-time distance data and preset baseline distance data when the boiler is not expanded, specifically includes the following steps B1-B2:

[0043] B1: Obtain the reference distance data of the boiler under preset reference operating conditions. It should be noted that it is essential to ensure the triangular shield is installed on a stable structure independent of the boiler's expansion body, such as a factory column, beam, or specially cast concrete foundation, to guarantee the absolute stability of the measurement reference. For example, after the boiler is installed, passes the hydrostatic test, and is in a cold, pressureless state before ignition, the measuring device is powered on and initialized, and then runs stably for a period of time (e.g., 30 minutes). Data is then continuously collected for 10 minutes, and the average value is taken as the reference distance data (D). X0 D Y0 D Z0 This is to eliminate initial jitter and single measurement error.

[0044] B2: Compare the real-time distance data with the reference distance data to obtain the expansion amount reflecting the displacement change of the boiler's measured component. For example, when the boiler is running, if the real-time measured distance in the X direction is 1518.5 mm, and the reference value is 1500.5 mm, then the expansion amount in that direction is 18.0 mm. Simultaneously calculate the expansion amounts in the Y and Z directions.

[0045] In this embodiment of the invention, the step of converting the expansion amount into a standard signal in step S300 specifically includes the following steps C1-C2:

[0046] C1: The standard signal is defined as a 4-20mA standard industrial current signal.

[0047] C2: Establish a preset mapping relationship between expansion amount and standard industrial signal, and perform conversion based on this relationship.

[0048] It should be noted that each sensor or its connected signal transmitter contains an internal digital-to-analog (D / A) converter and signal conditioning circuit. If the sensor itself does not directly output a 4-20mA signal, a separate signal transmitter is usually required to perform the conversion.

[0049] For example, assuming the maximum expansion in the Z-direction is 100mm, a 0mm expansion corresponds to an output current of 4mA, and a 100mm expansion corresponds to an output current of 20mA. When the measured Z-direction expansion is 60mm, the microprocessor inside the transmitter calculates the corresponding current value of 13.6mA and drives the constant current source circuit to output this current. This linear mapping relationship ensures the intuitiveness of the signal and its ease of interpretation by the DCS system. The independent signal transmitter can be field-mounted (suitable for direct installation near the sensor) or rail-mounted (suitable for installation in a control cabinet or instrument box). Its input interface typically supports multiple signal types, such as RS485, 0-10V, 0-5V, etc., which can be configured via jumpers or software; its output interface is a standard two-wire or three-wire 4-20mA current loop terminal, and each channel is usually equipped with an independent power indicator and signal status indicator for easy on-site debugging and troubleshooting.

[0050] In an alternative implementation, step S300 can also employ digital signal output, for example, via the HART (Addressable Remote Sensor High-Speed ​​Channel) protocol. This method allows digital information to be superimposed on a 4-20mA analog signal. For example, the DCS system can not only read a 13.6mA current value, but also, via HART commands, read precise information such as the 60.0mm expansion value, sensor internal temperature, and fault codes, enabling richer remote communication.

[0051] In this embodiment of the invention, step S400, in which the standard signal is sent to the monitoring system for display and subsequent monitoring and analysis, may specifically include the following steps D1-D4:

[0052] D1: Connect the 4-20mA signal to the DCS monitoring system via safety barriers and AI (analog input) cards, or connect the digital signal to the DCS via HART gateway / fieldbus cards.

[0053] Here, the AI ​​card is typically a high-precision (e.g., 16-bit resolution), multi-channel (e.g., 8-channel or 16-channel) analog input module that supports signal input with HART protocol and features inter-channel isolation and disconnection detection to ensure the accuracy and reliability of data acquisition. Its interface with the DCS main processor is usually implemented through the DCS system's internal high-speed backplane bus. The 4-20mA signal typically uses twisted-pair shielded cable, which, after being isolated by a field junction box and the intrinsically safe safety barrier, is physically connected to the AI ​​card terminal block inside the DCS cabinet.

[0054] D2: On the user interface of the DCS operator station, the three-dimensional expansion of key boiler components is intuitively presented using a combination of 3D dynamic schematic diagrams, real-time data display boxes, and historical trend curves. For example, the interface can display a simplified boiler model, on which the position of the measuring points will move slightly according to the real-time expansion data, while the precise values ​​of X, Y, and Z are displayed next to it, and the expansion curve of the past 72 hours can be viewed at any time.

[0055] D3: The monitoring system uses its internal logic operations to compare the real-time expansion amount with preset multi-level expansion thresholds. These thresholds are typically set based on boiler design specifications, historical operating data, and expert experience. For example, the first-level threshold for Y-direction expansion is set to 10mm (a warning), and the second-level threshold is set to 15mm (an audible and visual alarm). When the Y-direction expansion reaches 10.1mm, the corresponding value on the DCS screen turns yellow and the event is recorded; when it reaches 15.2mm, an alarm sound and flashing lights are triggered in the main control room.

[0056] D4: When a warning or alarm mechanism is triggered, the monitoring system further retrieves time difference data and, in conjunction with synchronously acquired key unit operating parameters such as boiler load, drum wall temperature difference, and heating rate, inputs it into the preset health status assessment model. It should be noted that the core of this model lies in distinguishing between the "quality" and "quantity" of the signal.

[0057] This health status assessment model can be implemented as a complex function block within an Advanced Application Programming (APC) software package or a Programmable Logic Controller (PLC) in a DCS system. It interacts with the DCS real-time database via a standardized OPC (OLE for Process Control) interface or an internal data bus interface.

[0058] For example, if the time difference data exhibits drastic, high-frequency random fluctuations when an alarm is triggered (indicating poor signal quality), while parameters such as boiler load and temperature remain stable, the model may determine that the sensor signal is interfered with (e.g., high-temperature steam momentarily affects the infrared light path) and prompt the operator with "Expansion alarm, but the measurement signal may be interfered with; please confirm in conjunction with other parameters or check the sensor status." Conversely, if the time difference data is stable (indicating good signal quality), but the expansion amount consistently exceeds the threshold and is strongly correlated with parameters such as the heating rate, it is determined to be a genuine expansion anomaly, and it is recommended to adjust the operating procedures or inspect the equipment itself. This diagnostic logic based on the correlation between signal quality and operating conditions is key to achieving intelligent early warning and avoiding misjudgments.

[0059] The output of the health status assessment model, such as status information like "normal expansion," "suspected interference," and "expansion obstruction warning," along with specific maintenance suggestion text, is written back to specific data tags or variables in the DCS via its data interface. The DCS operating interface can be configured to automatically change the color of the measuring point icon, pop up a detailed diagnostic information window, or automatically generate operation logs and maintenance work order suggestions based on the values ​​of these tags. For example, when the model outputs "suspected interference," the corresponding measuring point on the DCS interface will turn purple and flash, while a pop-up window will display: "Z-axis expansion signal fluctuates abnormally, inconsistent with operating conditions; it is recommended to check the cleanliness of the Z-axis sensor probe and cable connection."

[0060] This embodiment, through a detailed explanation of each stage of measurement, calculation, conversion, and monitoring, and the provision of multiple optional solutions, fully demonstrates the specificity, flexibility, and advancement of the technical solution of this invention. It not only solves many drawbacks of traditional monitoring methods, achieving high-precision, automated, and three-dimensional expansion measurement, but also improves the reliability and intelligence level of boiler expansion monitoring by introducing intelligent diagnostic logic based on underlying signal characteristics and operating parameters, providing strong technical support for ensuring the safety of large boilers.

[0061] Example 3, the third embodiment of the present invention, differs from the previous two embodiments in that: if the function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0062] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device.

[0063] More specific examples of computer-readable media (a non-exhaustive list) include: electrical connections (electronic devices) having one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which the program can be printed, because the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in computer memory.

[0064] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0065] Example 4, the fourth embodiment of the present invention, provides a three-dimensional remote measurement system for boiler expansion indication, comprising:

[0066] The data acquisition module is used to acquire real-time distance data of the boiler component under test in the first direction, the second direction, and the third direction using a measuring device installed on the boiler component under test;

[0067] The expansion calculation module is used to determine the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction based on the real-time distance data and the preset reference distance data when the boiler is not expanded.

[0068] The signal conversion module is used to convert the expansion amounts in the first direction, the second direction, and the third direction into standard signals;

[0069] The monitoring and communication module is used to send the standard signal to the monitoring system for display.

[0070] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A three-dimensional remote measurement method for boiler expansion indication, characterized in that: include, The real-time distance data of the boiler component under test is obtained using a measuring device installed on the component under test in the first direction, the second direction, and the third direction. The measuring device includes a hexahedron connected to the boiler component to be measured and a fixed triangular cover. The hexahedron is provided with three infrared measuring sensors facing the first direction, the second direction and the third direction respectively. The triangular cover has three reflective surfaces that are perpendicular to the first direction, the second direction and the third direction respectively. The first direction, the second direction and the third direction are perpendicular to each other. Based on the real-time distance data and the preset reference distance data when the boiler is not expanded, the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction is determined; The expansion amounts in the first direction, the second direction, and the third direction are converted into standard signals; The standard signal is sent to the monitoring system for display.

2. The three-dimensional remote measurement method for boiler expansion indication as described in claim 1, characterized in that: The method of acquiring real-time distance data of the boiler component under test using a measuring device mounted on the component under test includes: The infrared measurement sensor transmits measurement signals to the three corresponding reflective surfaces of the triangular shield and receives the echo signals reflected by the reflective surfaces. Determine the time difference between the transmission of the measurement signal and the reception of the echo signal; The real-time distance data is determined based on the time difference.

3. The three-dimensional remote measurement method for boiler expansion indication as described in claim 2, characterized in that: The step of determining the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction based on the real-time distance data and the preset reference distance data when the boiler is not expanded includes: Obtain the reference distance data of the boiler under preset reference operating conditions; The difference between the real-time distance data and the reference distance data is compared to obtain the expansion amount, which reflects the displacement change of the boiler component under test.

4. The three-dimensional remote measurement method for boiler expansion indication as described in claim 3, characterized in that: The step of converting the expansion amounts in the first direction, the second direction, and the third direction into standard signals includes: The standard signal is determined to be a standard industrial signal; Establish a preset mapping relationship between the expansion amount and the standard industrial signal; According to the preset mapping relationship, the expansion amount is converted into the standard industrial signal.

5. The three-dimensional remote measurement method for boiler expansion indication as described in claim 4, characterized in that: Sending the standard signal to the monitoring system for display includes: The standard industrial signals are connected to the monitoring system via a data interface; The expansion amounts in the first direction, the second direction, and the third direction are displayed in real time on the user interface of the monitoring system in a numerical or graphical manner.

6. The three-dimensional remote measurement method for boiler expansion indication as described in claim 4, characterized in that: The monitoring system uses the preset mapping relationship to reverse analyze the received standard industrial signal into the expansion amount, and compares the expansion amount with the preset multi-level expansion threshold in real time. When the expansion amount in any direction exceeds a corresponding preset expansion threshold, the monitoring system triggers a corresponding early warning or alarm mechanism, and generates and stores historical expansion trend data based on the expansion amount.

7. The three-dimensional remote measurement method for boiler expansion indication as described in claim 4, characterized in that: When the monitoring system triggers an early warning or alarm mechanism, the monitoring system further utilizes the time difference and, in conjunction with the synchronously acquired key operating parameters of the unit, inputs them into the preset health status assessment model. The health status assessment model analyzes the correlation between the change in the time difference and the change in the expansion amount to identify whether the abnormal expansion amount is caused by the actual deformation of the boiler body or by interference from the measurement environment, thereby outputting a boiler health status assessment result after distinguishing the interference factors.

8. A three-dimensional remote measurement system for boiler expansion indication, employing the three-dimensional remote measurement method for boiler expansion indication as described in any one of claims 1 to 7, characterized in that, include: The data acquisition module is used to acquire real-time distance data of the boiler component under test in the first direction, the second direction, and the third direction using a measuring device installed on the boiler component under test; The expansion calculation module is used to determine the expansion amount of the boiler component under test in the first direction, the second direction, and the third direction based on the real-time distance data and the preset reference distance data when the boiler is not expanded. The signal conversion module is used to convert the expansion amounts in the first direction, the second direction, and the third direction into standard signals; The monitoring and communication module is used to send the standard signal to the monitoring system for display.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the three-dimensional remote measurement method for boiler expansion indication as described in any one of claims 1 to 7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the three-dimensional remote measurement method for boiler expansion indication as described in any one of claims 1 to 7.

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