Boiler expansion monitoring system
By using a pull-rope sensor and control unit in the boiler expansion monitoring system, the problems of installation difficulty and reading error caused by the complex mechanical structure are solved, and high-precision boiler expansion monitoring is achieved.
Patent Information
- Application Number
- CN202511172218.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-21
- Publication Date
- 2025-11-18
AI Technical Summary
The existing boiler expansion monitoring technology has a complex mechanical structure, which makes installation difficult and causes pointer tilting, resulting in data reading errors.
A combination of pull-rope sensors and control units is used. Multiple pull-rope sensors are fixedly connected to the boiler target device on the same plane to form a real-time data matrix. The control unit receives and calculates the boiler expansion displacement value.
It simplifies the boiler expansion monitoring process, improves monitoring accuracy and reduces costs, eliminates human reading errors, and provides reliable expansion data.
Smart Images
Figure CN120970567A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of boiler expansion monitoring technology, and more specifically, to a boiler expansion monitoring system. Background Technology
[0002] Boiler expansion refers to the phenomenon where the volume of heated surface components increases due to temperature rise during boiler startup. During startup, the heated surface components are heated, and their temperature gradually increases, causing the metal materials to expand. Due to uneven heating rates and temperature distribution among the components, differences in expansion may occur. If expansion is hindered or the expansion amounts between components are inconsistent, it can lead to stress concentration and even equipment damage.
[0003] Existing boiler expansion monitoring technology based on mechanical displacement indicators has a complex mechanical structure, which directly leads to significant installation difficulties. In actual installation, the precise installation and debugging of multiple axial displacement sensors and drive components requires a considerable amount of time and effort from skilled technicians. More importantly, the pointer structure often tilts during movement. During boiler operation, the displacement of the expansion components causes the pointer of the mechanical displacement indicator to move to display the displacement value. However, due to the limitations of the mechanical structure and the complexity of the operating environment, the pointer is prone to tilting during movement. Once the pointer tilts, its position will not match the actual displacement direction, resulting in incorrect displacement data read by the operator. Summary of the Invention
[0004] In view of this, the purpose of this application is to provide a boiler expansion monitoring system that overcomes at least one of the above-mentioned defects.
[0005] In a first aspect, this application provides a boiler expansion monitoring system, including a data acquisition box and a control unit. The data acquisition box includes a housing and multiple pull-rope sensors. The housing is positioned at a monitoring location at the boiler site. A first through-hole is formed on the target surface of the data acquisition box. A boiler is arranged at the boiler site, and the monitoring location is set on the frame of the boiler so that one end of the target device of the boiler can pass through the first through-hole. Each pull-rope sensor is disposed on one side of the target surface so that the multiple pull-rope sensors are on the same plane. The measuring ends of the multiple pull-rope sensors are fixedly connected to one end of the target device passing through the first through-hole. The control unit receives the measurement data from the multiple pull-rope sensors to form a real-time data matrix and determines the displacement value of the boiler expansion based on the real-time data matrix.
[0006] In one possible implementation, the control unit includes: a gateway, located at the boiler site, the gateway being hardwired to each pull-rope sensor, the gateway being used to receive measurement data from the plurality of pull-rope sensors; and a server, wirelessly connected to the gateway, the server being used to generate the real-time data matrix from the measurement data and determine the displacement value of the boiler expansion based on the real-time data matrix.
[0007] In one possible implementation, the plurality of pull-rope sensors includes three pull-rope sensors, which are respectively disposed on a corresponding side of the target surface.
[0008] In one possible implementation, the measurement data includes real-time measurement values of each pull-wire sensor, wherein the control unit forms the real-time data matrix by: acquiring the real-time measurement values of each pull-wire sensor and combining each real-time measurement value into a multi-dimensional distance dataset to form the real-time data matrix, wherein the real-time measurement values include displacement components corresponding to multiple dimensions.
[0009] In one possible implementation, the control unit determines the displacement value of the boiler expansion by: obtaining the multidimensional coordinate value corresponding to the real-time measurement value based on the real-time data matrix; and comparing the multidimensional coordinate value with the initial coordinate value to obtain the displacement value.
[0010] In one possible implementation, the acquisition box at the monitoring location remains in a fixed position during boiler operation.
[0011] In one possible implementation, the target device is displaced as the boiler expands.
[0012] In one possible implementation, the data acquisition box further includes: a plurality of mounting brackets, the number of which is the same as the number of the plurality of pull-rope sensors, each mounting bracket being fixed to one side of the target surface, and each mounting bracket being used to fix the corresponding pull-rope sensor.
[0013] In one possible implementation, the collection box further includes a waterproof cloth covering the target surface, the waterproof cloth having a second through hole formed thereon.
[0014] In one possible implementation, the acquisition box includes multiple acquisition boxes and the monitoring position includes multiple monitoring positions. Each acquisition box is set at a corresponding monitoring position, and the measuring end of multiple pull-string sensors in each acquisition box is fixedly connected to one end of the target device of the corresponding monitoring position that passes through the first through hole of each acquisition box.
[0015] This application provides a boiler expansion monitoring system, including a data acquisition box and a control unit. The data acquisition box includes a housing and multiple pull-rope sensors. The housing is positioned at a monitoring location at the boiler site. A first through-hole is formed on the target surface of the data acquisition box. A boiler is located at the boiler site, and the monitoring location is positioned on the frame of the boiler so that one end of a target device of the boiler can pass through the first through-hole. Each pull-rope sensor is positioned on one side of the target surface, so that the multiple pull-rope sensors are on the same plane. The measuring ends of the multiple pull-rope sensors are fixedly connected to one end of the target device passing through the first through-hole. The control unit receives the measurement data from the multiple pull-rope sensors to form a real-time data matrix, and determines the displacement value of boiler expansion based on the real-time data matrix. This application simplifies the boiler expansion monitoring process, improves monitoring accuracy, and reduces monitoring costs.
[0016] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description
[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.
[0018] Figure 1 This is a schematic diagram of the boiler expansion monitoring system provided in the embodiments of this application; Figure 2 This is a schematic diagram of the structure of the data collection box provided in an embodiment of this application.
[0019] Reference numerals: 100-Data acquisition box; 101-Pull rope sensor; 102-Fixing frame; 103-Front cover; 200-Control unit; 201-Gateway; 202-Server; 3-Target device. Detailed Implementation
[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. Based on the embodiments of this application, every other embodiment obtained by those skilled in the art without inventive effort falls within the scope of protection of this application.
[0021] First, the applicable application scenarios of this application will be introduced. This application can be applied to boiler expansion monitoring technology.
[0022] Boiler expansion refers to the phenomenon where the volume of heated surface components increases due to temperature rise during boiler startup. During startup, the heated surface components are heated, and their temperature gradually increases, causing the metal materials to expand. Due to uneven heating rates and temperature distribution among the components, differences in expansion may occur. If expansion is hindered or the expansion amounts between components are inconsistent, it can lead to stress concentration and even equipment damage.
[0023] Existing boiler expansion monitoring technology based on mechanical displacement indicators has a complex mechanical structure, which directly leads to significant installation difficulties. In actual installation, the precise installation and debugging of multiple axial displacement sensors and drive components requires a considerable amount of time and effort from skilled technicians. More importantly, the pointer structure often tilts during movement. During boiler operation, the displacement of the expansion components causes the pointer of the mechanical displacement indicator to move to display the displacement value. However, due to the limitations of the mechanical structure and the complexity of the operating environment, the pointer is prone to tilting during movement. Once the pointer tilts, its position will not match the actual displacement direction, resulting in incorrect displacement data read by the operator.
[0024] Based on this, this application provides a boiler expansion monitoring system, which aims to simplify the boiler expansion monitoring process, improve monitoring accuracy, and reduce monitoring costs.
[0025] Please see Figure 1 , Figure 1 This is a schematic diagram of the structure of a boiler expansion monitoring system provided in an embodiment of this application. Figure 1 As shown in the figure, the boiler expansion monitoring system provided in this application embodiment includes: a data acquisition box 100 and a control unit 200.
[0026] The specific structure of the data collection box 100 is as follows: Figure 2As shown, Figure 2 This is a schematic diagram of the structure of the data collection box 100 provided in the embodiment of this application.
[0027] The housing is set at the monitoring position at the boiler site. The front cover 103 of the acquisition box 100 forms a target surface with a first through hole. A boiler is arranged at the boiler site, and the monitoring position is set on the frame of the boiler so that one end of the target device 3 of the boiler can pass through the first through hole. A waterproof cloth is covered on the target surface of the housing, and a second through hole is formed on the waterproof cloth so that when one end of the target device 3 passes through the first and second through holes, the housing forms a sealed space.
[0028] Specifically, the housing is fixed to the monitoring position by welding. The monitoring position can be set at a location that is not affected by boiler expansion, so that the acquisition box 100 at the monitoring position remains fixed in position during boiler operation and will not be displaced. The target device 3 can be a component that can be affected by boiler expansion, so as to indirectly monitor the relative displacement of boiler expansion through the component. The target component is preferably the steel pipe of the boiler.
[0029] Each pull-wire sensor 101 is disposed on one side of the target surface so that the plurality of pull-wire sensors 101 are in the same plane, and the measuring end of the plurality of pull-wire sensors 101 is fixedly connected to one end of the target device 3 passing through the first through hole.
[0030] Specifically, a mounting bracket 102 is provided on the side of the target surface. The mounting bracket 102 is fixed to the side by screws, and a corresponding pull rope sensor 101 is fixed to each mounting bracket 102 by screws.
[0031] In a preferred embodiment of this application, the data acquisition box 100 includes multiple data acquisition boxes, and multiple monitoring positions can be set. Each data acquisition box 100 is set at a corresponding monitoring position. The measuring end of multiple pull-rope sensors 101 of each data acquisition box 100 is fixedly connected to one end of the target device 3 of the corresponding monitoring position that passes through the first through hole of each data acquisition box 100, thereby ensuring the accuracy of unique monitoring.
[0032] The control unit 200 is used to receive measurement data from the plurality of pull rope sensors 101 to form a real-time data matrix, and to determine the displacement value of boiler expansion based on the real-time data matrix.
[0033] In a preferred embodiment of this application, the control unit 200 includes a gateway 201 and a server 202.
[0034] Gateway 201 is installed at the boiler site. Gateway 201 is hardwired to each pull rope sensor 101 and is used to receive measurement data from the plurality of pull rope sensors 101.
[0035] Server 202 is wirelessly connected to gateway 201. Server 202 is used to generate the real-time data matrix from the measurement data and determine the displacement value of boiler expansion based on the real-time data matrix.
[0036] In a preferred embodiment of this application, the acquisition box 100 includes multiple acquisition boxes, and the monitoring position includes multiple monitoring positions. Each acquisition box 100 is set at a corresponding monitoring position, and the measuring end of multiple pull rope sensors 101 of each acquisition box 100 is fixedly connected to one end of the target device 3 of the corresponding monitoring position that passes through the first through hole of each acquisition box 100.
[0037] Specifically, each data acquisition box 100 is connected to a bus via RS485 and communicates with the edge gateway 201 via Modbus RTU. The edge gateway 201 acquires displacement data and transmits the data to the server 202 via 4G / 5G wireless. The server runs an algorithm to convert the distance values into spatial displacement, stores them in the database, and displays them on the system platform.
[0038] The following section uses three pull-rope sensors 101 as an example to introduce the specific process of calculating the displacement value of boiler expansion.
[0039] The boiler has three pull-rope sensors 101 at positions p1x, p1y, p1z, p2x, p2y, p2z, p3x, p3y, and p3z, with measured values r1, r2, and r3 for the three pull ropes. Let the coordinates of the measured positions be x, y, and z.
[0040] Establish three distance equations (1.1) (1.2) (1.3) Subtracting equation (1.3) from equation (1.1) and subtracting equation (1.3) from equation (1.2) yields the following equation: (2.1) (2.2) in:
[0041]
[0042]
[0043]
[0044]
[0045]
[0046]
[0047] The three pull-string sensors 101 treat equations (2.1) and (2.2) as a system of equations with x and y as unknowns, and obtain: (3.1) (3.2) Where d1, d2, e1, and e2 are:
[0048]
[0049]
[0050]
[0051] Substituting equations (3.1) and (3.2) into equation (1.3), we obtain a system of quadratic equations in z, which gives: (4.1) Where a, b, and c are respectively:
[0052]
[0053]
[0054] Take a value of z greater than 0 and substitute it back into (3.1) and (3.2) to obtain the values of x and y. Subtract these values from the initial coordinate values to obtain the multidimensional displacement values.
[0055] It should be noted that since the equation may have two solutions that are symmetrical about the plane formed by the pull rope sensor 101, it is necessary to ensure that the position of the fixed pull rope head of the target device 3 does not cross the plane of the target surface during the movement.
[0056] Compared with existing boiler expansion monitoring technologies, this application adopts a three-layer distributed architecture: the front-end boiler expansion acquisition box requires only three coplanarly arranged pull-rope sensors, connected to the boiler heating surface components via steel pipes, significantly simplifying the mechanical structure; the middle edge gateway collects data from multiple acquisition boxes via RS485 bus, and then transmits it wirelessly to the back-end server via 4G / 5G. This architecture significantly improves system scalability—adding monitoring points only requires connecting a new acquisition box, without modifying the entire system. Wireless transmission completely eliminates cable constraints, ensuring real-time and reliable data transmission under high temperature and high pressure environments. The server-side uses a three-dimensional spatial trilateration algorithm to convert the length values of the three pull ropes into precise coordinates of the measured point, automatically calculating the three-dimensional displacement by comparing it with the initial cold-state coordinates, eliminating errors from manual readings. This technical solution reduces installation costs through structural simplification, provides a reliable basis for combustion optimization and pressure rise curve development, effectively prevents expansion exceeding limits and leakage accidents, and extends boiler life.
[0057] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.
[0058] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the shown or discussed mutual couplings, direct couplings, or communication connections may be through some communication interfaces; indirect couplings or communication connections between devices or units may be electrical, mechanical, or other forms.
[0059] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.
[0060] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.
[0061] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a processor-executable, non-volatile, computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion 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 this application. 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] Finally, it should be noted that the above-described embodiments are merely specific implementations of this application, used to illustrate the technical solutions of this application, and not to limit them. The scope of protection of this application is not limited thereto. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments, or make equivalent substitutions for some of the technical features, within the scope of the technology disclosed in this application. Such modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.
Claims
1. A boiler expansion monitoring system, characterized in that, It includes a data acquisition box and a control unit. The data acquisition box includes a box body and multiple pull-string sensors. The box is set at the monitoring position at the boiler site. A first through hole is opened on the target surface of the acquisition box. A boiler is arranged at the boiler site. The monitoring position is set on the frame of the boiler so that one end of the target device of the boiler can pass through the first through hole. Each pull-wire sensor is disposed on one side of the target surface so that the multiple pull-wire sensors are in the same plane, and the measuring end of the multiple pull-wire sensors is fixedly connected to one end of the target device passing through the first through hole; The control unit receives measurement data from the multiple pull-rope sensors to form a real-time data matrix, and determines the displacement value of the boiler expansion based on the real-time data matrix.
2. The system according to claim 1, characterized in that, The control unit includes: A gateway is installed at the boiler site. The gateway is hardwired to each pull-rope sensor and is used to receive measurement data from the plurality of pull-rope sensors. The server is wirelessly connected to the gateway. The server is used to generate the real-time data matrix from the measurement data and determine the displacement value of the boiler expansion based on the real-time data matrix.
3. The system according to claim 1, characterized in that, The plurality of pull-rope sensors includes three pull-rope sensors, which are respectively disposed on the corresponding side of the target surface.
4. The system according to claim 1, characterized in that, The measurement data includes real-time measurements from each pull-cord sensor. The control unit forms the real-time data matrix in the following manner: The real-time measurement values of each pull-wire sensor are acquired, and each real-time measurement value is combined into a multi-dimensional distance dataset to form the real-time data matrix. The real-time measurement values include displacement components corresponding to multiple dimensions.
5. The system according to claim 4, characterized in that, The control unit determines the displacement value of the boiler expansion in the following way: Based on the real-time data matrix, the multi-dimensional coordinate values corresponding to the real-time measurement values are obtained; The displacement value is obtained by comparing the multidimensional coordinate value with the initial coordinate value.
6. The system according to claim 1, characterized in that, The data acquisition box at the monitoring location remains in a fixed position during boiler operation.
7. The system according to claim 1, characterized in that, The target device shifts as the boiler expands.
8. The system according to claim 1, characterized in that, The collection box also includes: Multiple mounting brackets, the number of which is the same as the number of multiple pull-rope sensors, each mounting bracket being fixed to one side of the target surface, each mounting bracket being used to fix the corresponding pull-rope sensor.
9. The system according to claim 1, characterized in that, The collection box also includes: A waterproof cloth is placed over the target surface, and a second through hole is formed on the waterproof cloth.
10. The system according to claim 1, characterized in that, The acquisition box includes multiple acquisition boxes, and the monitoring position includes multiple monitoring positions. Each acquisition box is set at a corresponding monitoring position. The measuring end of multiple pull-string sensors in each acquisition box is fixedly connected to one end of the target device of the corresponding monitoring position that passes through the first through hole of each acquisition box.