Boiler combustion digital monitoring and three-dimensional visualization system
By utilizing a digital monitoring and 3D visualization system for boiler combustion, and employing multiple sensors and AI modeling technology, the system enables full-dimensional digital monitoring and early warning of the boiler combustion process. This solves the problems of data lag and efficiency optimization in traditional monitoring methods, and improves the accuracy and efficiency of fault identification and anomaly location.
Patent Information
- Application Number
- CN202511081750.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-04
- Publication Date
- 2025-11-18
AI Technical Summary
In the existing boiler combustion process, traditional monitoring methods rely on manual inspections and two-dimensional charts, resulting in data lag, poor global coverage, difficulty in quickly locating anomalies, lack of intelligent decision-making supported by real-time data, and combustion efficiency optimization relying on experience-based adjustments.
The system employs a digital monitoring and 3D visualization system for boiler combustion. It collects data through sensors such as high-temperature infrared thermocouples, laser spectral gas analyzers, differential pressure transmitters, vibration sensors, and flame imaging cameras. Combined with an AI combustion 3D modeling engine and LSTM algorithm, it achieves full-dimensional digital monitoring and early warning, and provides a 3D visualization interface and real-time optimization adjustments.
It improves the accuracy of fault identification, lowers the threshold for operation and maintenance, shortens the training cycle, reduces resource waste, reduces exhaust emissions, enables timely alarms and rapid anomaly location, and supports intelligent decision-making.
Smart Images
Figure CN120976491A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the field of boiler combustion technology, in particular to a boiler combustion digital monitoring and three-dimensional visualization system. BACKGROUND
[0002] A boiler is an energy conversion device. The energy input into the boiler includes chemical energy in fuel and electric energy. The boiler outputs steam, high-temperature water or organic heat carrier with certain heat energy. The original meaning of boiler is a water container heated on a fire. The furnace refers to the place where fuel is burned. The boiler includes a pot and a furnace. The hot water or steam generated in the boiler can directly provide the required heat energy for industrial production and people's life. Alternatively, the steam power device can be used to convert the heat energy into mechanical energy, or the mechanical energy can be converted into electric energy through a generator. The boiler that provides hot water is called a hot water boiler, which is mainly used for life and a small amount of application in industrial production. The boiler that generates steam is called a steam boiler, which is commonly referred to as a boiler and is mainly used in thermal power plants, ships, locomotives and industrial and mining enterprises
[0003] With the rapid development of economy, the thermal equipment is developing towards super large capacity and high parameters, and each device is becoming more and more complex, which improves the quality of the heating production process of residents. The visualization technology of the boiler combustion state plays an important role in the economy, safety and combustion process of the pulverized coal boiler production process.
[0004] In the prior art, the boiler combustion process involves complex fluid dynamics, chemical reactions and heat and mass transfer phenomena. The traditional monitoring method relies on manual inspection and local sensors, and has problems such as data lag, poor globality, and untimely discovery of hidden dangers. The combustion state is mainly displayed through two-dimensional charts, which lacks intuitive three-dimensional dynamic simulation, making it difficult for operation and maintenance personnel to quickly locate abnormalities. In addition, the optimization of combustion efficiency relies on experience adjustment, and lacks intelligent decision-making supported by real-time data, so the present application provides a boiler combustion digital monitoring and three-dimensional visualization system to solve the above problems. SUMMARY
[0005] (I) Technical problems solved
[0006] In view of the deficiencies in the prior art, the present application provides a boiler combustion digital monitoring and three-dimensional visualization system to solve the problems proposed in the background art.
[0007] (II) Technical solutions
[0008] In order to achieve the above purpose, the present application specifically adopts the following technical solutions:
[0009] The application discloses a boiler combustion digital monitoring and three-dimensional visualization system.
[0010] Further, the server comprises a single-chip microcomputer, an A / D conversion module, a data processing module, an image processing module, a storage, a comparison module and a wireless communication module.
[0011] Further, the data acquisition unit comprises a high-temperature infrared thermocouple, a laser spectrum gas analyzer, a differential pressure transmitter, a vibration sensor and a flame imaging camera, wherein the high-temperature infrared thermocouple, the laser spectrum gas analyzer, the differential pressure transmitter, the vibration sensor and the flame imaging camera are all installed on the boiler, and the high-temperature infrared thermocouple, the laser spectrum gas analyzer, the differential pressure transmitter, the vibration sensor and the flame imaging camera are electrically connected with the single-chip microcomputer.
[0012] Further, the high-temperature infrared thermocouple is arranged at four corners of a furnace, adopts a cross grid layout, has a longitudinal spacing of 2 m (a total of 8 layers) and a transverse spacing of 1.2 m, the high-temperature infrared thermocouple sleeve adopts Inconel 600 material, and has an insertion depth of greater than or equal to 500 mm, and a ceramic protective cover is additionally arranged outside the high-temperature infrared thermocouple.
[0013] Further, the laser spectrum gas analyzer is arranged at an entrance and an exit of a flue, the laser spectrum gas analyzer is automatically zero-point calibrated every day, the laser spectrum gas analyzer is purged by using nitrogen, the differential pressure transmitter is installed at an entrance of an air chamber and a burner nozzle, the vibration sensor is fixedly installed on a furnace wall, the flame imaging camera is installed outside a fire observation hole of the boiler, and a flame image is identified for combustion stability through a convolutional neural network and cross-verified with sensor data.
[0014] Further, the flame imaging camera is installed on a pneumatic rotating holder, and the flame imaging camera is provided with an automatic dust cleaning assembly.
[0015] Further, the cloud analysis module is based on an AI combustion three-dimensional modeling engine, fuses CFD (computational fluid dynamics) simulation data and real-time monitoring data, and dynamically generates a three-dimensional model of a combustion field.
[0016] Further, the display unit comprises a computer and a mobile terminal, the computer and the mobile terminal support a visualization interface of a Web end, provide functions such as a combustion efficiency thermodynamic diagram and a pollutant distribution cloud diagram, and map parameters such as temperature and CO concentration to model colors and particle effects in real time.
[0017] Further, the early warning unit comprises an audible and visual alarm and an abnormal early warning pop-up window, the audible and visual alarm is installed in the server and the monitoring room, and the abnormal early warning pop-up window is popped up through a computer and a mobile terminal.
[0018] Further, the optimization adjustment module predicts the coking and flameout risks through an LSTM algorithm and pushes an alarm to the display unit in advance by 30 minutes.
[0019] (Three) beneficial effects
[0020] Compared with the prior art, the present application provides a boiler combustion digital monitoring and three-dimensional visualization system, which has the following beneficial effects:
[0021] The present application collects information in the boiler through a server and a data acquisition unit, constructs a three-dimensional perception network, and is equipped with a cloud analysis module, a display unit, an early warning unit and an optimization adjustment module, so as to realize full-dimensional digitalization of the combustion process, greatly improve the fault recognition accuracy, reduce the operation and maintenance threshold through three-dimensional visualization, shorten the training cycle, greatly save resources, reduce waste gas emission pollution, increase the early warning function, timely alarm, timely processing by the staff, rapid positioning of abnormalities, real-time data support for intelligent decision-making. BRIEF DESCRIPTION OF DRAWINGS
[0022] Figure 1 It is a control system structure schematic diagram of the present application;
[0023] Figure 2 It is a control method flow structure schematic diagram of the present application. DETAILED DESCRIPTION
[0024] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.
[0025] EMBODIMENT
[0026] As Figure 1 and Figure 2As shown, the boiler combustion digital monitoring and three-dimensional visualization system provided by one embodiment of the present application comprises a server, the server is electrically connected with a data acquisition unit, the server is electrically connected with a cloud analysis module, the server is network connected with a display unit, the server is network connected with a warning unit through a 5G network, an optimization adjustment module is arranged in the server, and the server makes the data acquisition unit collect data once every 5 seconds and transmit the data to the cloud through a 5G private network.
[0027] As shown in Figure 1 and Figure 2 In some embodiments, the server comprises a single-chip microcomputer, an A / D conversion module, a data processing module, an image processing module, a storage, a comparison module and a wireless communication module, and the single-chip microcomputer is electrically connected with the A / D conversion module, the data processing module, the image processing module, the storage and the wireless communication module.
[0028] In this embodiment, the collected values and pictures are processed by the A / D conversion module, the data processing module and the image processing module, and can be stored and compared with the preset values in the storage through the comparison module, and the display unit and the warning unit can be connected through the wireless communication module, an embedded server is adopted to realize data noise reduction and normalization, a preliminary combustion state analysis algorithm is built-in, and an MSP430 series single-chip microcomputer is adopted.
[0029] As shown in Figure 1 and Figure 2 In some embodiments, the data acquisition unit comprises a high-temperature infrared thermocouple, a laser spectrum gas analyzer, a differential pressure transmitter, a vibration sensor and a flame imaging camera, the high-temperature infrared thermocouple, the laser spectrum gas analyzer, the differential pressure transmitter, the vibration sensor and the flame imaging camera are all installed on the boiler, and the high-temperature infrared thermocouple, the laser spectrum gas analyzer, the differential pressure transmitter, the vibration sensor and the flame imaging camera are electrically connected with the single-chip microcomputer.
[0030] In this embodiment, the high-temperature infrared thermocouple, the laser spectrum gas analyzer and the differential pressure transmitter monitor the temperature field, the flue gas composition and the pressure distribution, the vibration sensor detects the oscillation frequency of the flame, the flame imaging camera takes pictures of the flame, and the flame imaging camera adopts an infrared / visible light dual-spectrum camera.
[0031] As shown in Figure 1 and Figure 2 In some embodiments, the high-temperature infrared thermocouple is arranged at the four corners of the furnace, adopts a cross-grid layout, the longitudinal spacing is 2m (a total of 8 layers), the transverse spacing is 1.2m, the high-temperature infrared thermocouple sleeve adopts Inconel 600 material, the insertion depth is greater than or equal to 500mm, and a ceramic protective cover is additionally installed outside the high-temperature infrared thermocouple.
[0032] In this embodiment, the high-temperature infrared thermocouple is evenly arranged, the collected temperature information is more comprehensive, and the high-temperature infrared thermocouple is not easy to be damaged, prolonging the service life.
[0033] As shown in Figure 1 and Figure 2 shown, in some embodiments, the laser spectrum gas analyzer is arranged at the entrance and exit of the flue, the laser spectrum gas analyzer is automatically calibrated to zero every day, the laser spectrum gas analyzer is purged with nitrogen, the differential pressure transmitter is installed at the entrance of the air chamber and the burner nozzle, the vibration sensor is fixedly installed on the furnace wall, the flame imaging camera is installed outside the observation hole of the boiler, and the flame image is identified by a convolutional neural network to identify the combustion stability, and cross-validated with sensor data.
[0034] In this embodiment, the laser spectrum gas analyzer can accurately collect gas information, the laser spectrum gas analyzer is not easy to be covered and blocked by dust, the differential pressure transmitter can accurately check the air pressure in the boiler, the vibration sensor can accurately monitor the vibration frequency of the boiler and the flame, and the flame imaging camera can take clearer flame.
[0035] As shown in Figure 1 and Figure 2 shown, in some embodiments, the flame imaging camera is installed on a pneumatic rotating holder, and the flame imaging camera is provided with an automatic dust cleaning assembly.
[0036] In this embodiment, the flame imaging camera can rotate to comprehensively take pictures of the flame in the boiler, and the automatic dust cleaning assembly can clean the dust on the lens of the flame imaging camera, ensuring that the lens of the flame imaging camera takes clear pictures.
[0037] As shown in Figure 1 and Figure 2 shown, in some embodiments, the cloud analysis module is based on an AI combustion three-dimensional modeling engine, which combines CFD (computational fluid dynamics) simulation data and real-time monitoring data to dynamically generate a three-dimensional model of the combustion field.
[0038] In this embodiment, the dynamically generated three-dimensional model of the combustion field can more intuitively view the combustion in the boiler.
[0039] As shown in Figure 1 and Figure 2 shown, in some embodiments, the display single includes a computer and a mobile terminal, the computer and the mobile terminal support a visual interface on the Web side, provide functions such as combustion efficiency thermodynamic map and pollutant distribution cloud map, and map parameters such as temperature and CO concentration to model color and particle effect in real time.
[0040] In the embodiment, the computer and the mobile terminal can view the boiler combustion information through the visual interface of the Web end, the temperature field contour is mapped by red-yellow-blue gradient, and the CO concentration particle flow is simulated by dynamic trajectory, so as to realize digital monitoring and three-dimensional visualization.
[0041] As shown in Figure 1 and Figure 2 , in some embodiments, the early warning unit includes an audible and visual alarm installed in the server and the monitoring room, and an abnormal early warning pop-up window popped up through the computer and the mobile terminal.
[0042] In the embodiment, the audible and visual alarm can remind the staff near the boiler and in the monitoring room by sound and light, and send a pop-up window through the computer and the mobile terminal, so that the staff can find the problems of the boiler in time.
[0043] As shown in Figure 1 and Figure 2 , in some embodiments, the optimization adjustment module predicts the coking and flameout risk by the LSTM algorithm and pushes the alarm to the display unit 30 minutes in advance.
[0044] In the embodiment, the coking and flameout of the boiler can be accurately reminded, and the genetic algorithm is combined to generate a combustion parameter optimization scheme.
[0045] In use, the high-temperature infrared thermocouple, laser spectrum gas analyzer and differential pressure transmitter in the data acquisition unit are monitored by the single-chip microcomputer in the server to monitor the temperature field of the boiler, the composition of the flue gas, the pressure distribution, etc. The vibration sensor detects the oscillation frequency of the flame, and the flame imaging camera takes pictures of the flame, and feeds back the information to the single-chip microcomputer. The collected values and pictures are processed by the A / D conversion module, the data processing module and the image processing module, and can be stored and compared with the preset values in the storage through the comparison module. The single-chip microcomputer makes the collected information pass through the combustion three-dimensional modeling engine in the cloud analysis module, fuses the CFD simulation data and real-time monitoring data, and dynamically generates a three-dimensional model of the combustion field. These numbers and three-dimensional models are displayed through the visual interface of the computer and the Web end of the mobile terminal in the display unit to display the boiler combustion information, making it easy for staff to view. The temperature field contour is mapped by red-yellow-blue gradient, and the CO concentration particle flow is simulated by dynamic trajectory. Digital monitoring and three-dimensional visualization are realized. The server collects data every 5 seconds and transmits it to the cloud through the 5G private network. When the local temperature in the boiler is greater than 200 degrees Celsius, the server makes the sound and light alarm in the warning unit sound and light alarm to remind the staff near the boiler and in the monitoring room, and sends a pop-up window through the computer and the mobile terminal to remind the staff to find the problems of the boiler in time. If the optimization adjustment module predicts that the probability of boiler coking is greater than 80% through the LSTM algorithm, it will push the information to the display unit 30 minutes in advance and warn through the warning unit. The ammonia injection system is linked to push the maintenance work order to remind the staff.
[0046] In summary, the boiler combustion digital monitoring and three-dimensional visualization system collects information in the boiler through the server and the data acquisition unit, constructs a three-dimensional perception network, and through the cloud analysis module, the display unit, the warning unit and the optimization adjustment module, realizes full-dimensional digitalization of the combustion process, greatly improves the accuracy of fault identification, reduces the operation and maintenance threshold through three-dimensional visualization, shortens the training cycle, greatly saves resources, reduces waste gas emission pollution, increases the warning function, can alarm in time, the staff can handle in time, can quickly locate the abnormality, and the real-time data supports intelligent decision-making.
[0047] Those skilled in the art can understand that all or some of the steps in the method disclosed above and the functional modules / units in the system and device can be implemented by software, firmware, hardware, or a combination thereof. In a hardware implementation, the division between the functional modules / units referred to in the above description does not necessarily correspond to the division of physical components; for example, one physical component can have multiple functions, or one function or step can be performed by several physical components in cooperation. Some or all of the physical components can be implemented as software executed by a processor, such as a central processing unit, a digital signal processor, or a microprocessor, or as hardware, or as an integrated circuit, such as an application-specific integrated circuit. Such software can be distributed on computer-readable storage media, which can include computer storage media (or non-transitory media) and communication media (or transitory media).
[0048] The computer readable program instructions described herein can be downloaded to respective computing / processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and / or a wireless network. The network can comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and / or edge servers. A network adapter card or network interface in each computing / processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing / processing device.
[0049] The computer readable program instructions described herein can be downloaded to respective computing / processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and / or a wireless network. The network can comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and / or edge servers. A network adapter card or network interface in each computing / processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing / processing device.
[0050] These computer readable program instructions can be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions can also be stored in a computer readable storage medium that can include a non-transitory medium that can be a computer readable storage medium having no data signals on it. The instructions can be executed by one or more processors to generate means for carrying out the functions / acts specified in the flowchart and / or block diagram block or blocks.
[0051] The computer readable program instructions can also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable data processing apparatus or other device to produce a computer implemented process such that the instructions which execute on the computer, other programmable data processing apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.
[0052] The flow diagrams and the block diagrams in the drawings are presented to illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to the present application. In this regard, each block in the flow diagrams and the block diagrams can represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logic functions (s). It should also be noted that in some alternative implementations, the functions noted in the
[0053] Example embodiments have been disclosed and, although a particular order was described in the examples, this was done merely for ease of description and is in no way meant to limit the scope of the example embodiments described. In some instances, well-known methods, structures and techniques have not been described in detail in order to avoid obscuring the example embodiments described. Although the example embodiments have been described with reference to the order described, it should be understood that no particular order is, in fact, required for these example embodiments to work properly. In some instances, well-known methods, structures and techniques have not been described in detail in order to avoid obscuring the example embodiments described. Also, although the example embodiments have been described with reference to particular means, materials and / or processes, this is by no means a limitation on the contemplated embodiments, and indeed, any process that accomplishes the same functions can be substituted. Therefore, person skilled in the art will appreciate that the foregoing and various other examples, modifications and / or improvements can be made thereto without departing from the scope of the application. Accordingly, the application is not limited to that precisely as shown and described.
Claims
1. A boiler combustion digital monitoring and 3D visualization system comprising a server, characterized by: The server is electrically connected to the data acquisition unit, the server is electrically connected to the cloud analysis module, the server is network connected to the display unit, the server is network connected to the early warning unit via a 5G network, and the server is equipped with an optimization and adjustment module.
2. The boiler combustion digital monitoring and three-dimensional visualization system of claim 1, wherein: The server includes a microcontroller, an A / D conversion module, a data processing module, an image processing module, a storage device, a comparison module, and a wireless communication module. The microcontroller is electrically connected to the A / D conversion module, the data processing module, the image processing module, the storage device, and the wireless communication module.
3. The boiler combustion digital monitoring and three-dimensional visualization system of claim 1, wherein: The data acquisition unit includes a high-temperature infrared thermocouple, a laser spectrometer gas analyzer, a differential pressure transmitter, a vibration sensor, and a flame imaging camera. The high-temperature infrared thermocouple, laser spectrometer gas analyzer, differential pressure transmitter, vibration sensor, and flame imaging camera are all installed on the boiler. The high-temperature infrared thermocouple, laser spectrometer gas analyzer, differential pressure transmitter, vibration sensor, and flame imaging camera are electrically connected to a single-chip microcomputer.
4. The boiler combustion digital monitoring and three-dimensional visualization system of claim 3, wherein: The high-temperature infrared thermocouples are arranged at the four corners of the furnace in a cross-grid layout with a longitudinal spacing of 2m (8 layers in total) and a transverse spacing of 1.2m. The high-temperature infrared thermocouple sheaths are made of Inconel 600 material with an insertion depth of ≥500mm. A ceramic protective cover is installed on the outside of the high-temperature infrared thermocouples.
5. The boiler combustion digital monitoring and three-dimensional visualization system of claim 3, wherein: The laser spectrometer gas analyzer is installed at the flue inlet and outlet. The laser spectrometer gas analyzer is automatically zero-calibrated daily. The laser spectrometer gas analyzer is purged with nitrogen. The differential pressure transmitter is installed at the air chamber inlet and the burner nozzle. The vibration sensor is fixedly installed on the furnace wall. The flame imaging camera is installed on the outside of the boiler's observation hole. The flame image is used to identify combustion stability through a convolutional neural network and cross-validated with sensor data.
6. The boiler combustion digital monitoring and three-dimensional visualization system of claim 3, wherein: The flame imaging camera is mounted on a pneumatic rotating gimbal and is equipped with an automatic dust removal component.
7. The boiler combustion digital monitoring and three-dimensional visualization system of claim 1, wherein: The cloud-based analysis module is based on an AI-powered combustion 3D modeling engine that integrates CFD (Computational Fluid Dynamics) simulation data with real-time monitoring data to dynamically generate a 3D model of the combustion field.
8. The boiler combustion digital monitoring and three-dimensional visualization system of claim 1, wherein: The display unit includes a computer and a mobile terminal. The computer and mobile terminal support a web-based visualization interface, providing functions such as combustion efficiency heat maps and pollutant distribution cloud maps, and mapping parameters such as temperature and CO concentration to model colors and particle effects in real time.
9. The boiler combustion digital monitoring and three-dimensional visualization system according to claim 1, characterized in that: The early warning unit includes an audible and visual alarm and an abnormal warning pop-up window. The audible and visual alarm is installed in the server and monitoring room, and the abnormal warning pop-up window is displayed via computer and mobile terminal.
10. The boiler combustion digital monitoring and three-dimensional visualization system according to claim 1, characterized in that: The optimization and adjustment module uses the LSTM algorithm to predict the risk of coking and flameout, and pushes an alarm to the display unit 30 minutes in advance.