Ternary parameter intelligent detection end cover for capacitor transformer fault monitoring

Abstract

The invention discloses a ternary parameter intelligent detection end cover for fault monitoring of a capacitive transformer. The end cover integrates a hollow body, an axial flow guide channel, a multi-stage Tesla rectification assembly, an in-situ multi-parameter monitoring cavity and an elastic threshold pressure regulation and control cavity. Gas enters from the bottom, and stable one-way flow is realized after rectification; and the temperature and pressure in the monitoring cavity and the hydrogen detection unit can perform in-situ continuous monitoring. When the air pressure exceeds a set threshold value, the regulation and control cavity elastically responds to drive the lateral one-way discharge valve to be opened for exhausting, passive slow release is achieved, and reverse flow is prevented. According to the design, gas collection, rectification, detection and safe emission are highly integrated in the end cover, the original structure of equipment does not need to be changed, and the device has the advantages of being fast in response, high in environmental adaptability, compact in structure, high in safety and the like and is suitable for online state monitoring and safety early warning of equipment such as new energy equipment and a hydrogen storage system.

Description

Technical Field

[0001] This invention belongs to the field of industrial equipment online monitoring and safety management technology, and in particular relates to a three-dimensional parameter intelligent detection end cap for monitoring the faults of capacitive transformers used in pressure vessels and sealed industrial cavities. It is used to collect internal gas parameters of the equipment in real time and perform unidirectional discharge under abnormal pressure conditions, so as to improve the operational reliability and safety level of the equipment. Background Technology

[0002] During the operation of various industrial equipment, the internal media (such as air, hydrogen, combustible gas, process gas, etc.) are often under certain temperature, pressure, or concentration conditions, and their operating status is crucial to equipment safety. In order to monitor the internal condition of the equipment in real time, it is usually necessary to install temperature sensors, pressure sensors, or gas leak detection devices. However, traditional detection methods often require additional drilling or modification of the equipment structure, which not only increases manufacturing costs but also introduces potential leakage hazards.

[0003] Many enclosed devices often have small threaded holes for maintenance, pressure relief, or ventilation. However, these holes are mostly blocked by ordinary end caps during normal operation and are not effectively utilized. Although some industries have attempted to install sensors in these holes, two prominent problems generally exist: first, the limited internal space makes it difficult to achieve multi-parameter collaborative detection; second, existing solutions lack effective gas guiding and rectifying structures, resulting in slow sensor response, unstable detection, and even contamination.

[0004] Equipment containing flammable or reactive gases often has hazardous internal gases, such as hydrogen, which diffuses rapidly, accumulates easily, and is highly flammable. Therefore, extremely high requirements are placed on gas flow paths, monitoring accuracy, response speed, and prevention of backflow from external contaminants. However, traditional exhaust structures often employ simple channels or mechanical valves, resulting in significant gas flow disturbances, insufficient reverse resistance, and a high risk of backflow contamination. Furthermore, these structures cannot ensure that the gas within the monitoring chamber is constantly replaced by the true and effective internal medium of the equipment, leading to distorted monitoring results.

[0005] The Tesla structure, as an asymmetric fluid guiding component, features low forward resistance and high reverse resistance, enabling unidirectional gas flow and backflow prevention. However, existing Tesla structures are mostly used in piping systems and are difficult to implement in highly integrated, space-constrained small structures like end caps. Furthermore, existing Tesla units lack targeted optimizations in areas such as multi-stage combination, rectification efficiency improvement, and micro-cavity stability, and cannot meet the stringent requirements of industrial applications.

[0006] Therefore, there is an urgent need for a new structure that can completely replace ordinary end caps and achieve path guidance, rectification and anti-reverse flow, parameter detection and pressure threshold discharge within a limited space. This structure would allow for installation without additional openings or changes to the equipment structure, and would also feature rapid response, high reliability, strong anti-pollution capability, and long-term stable operation. Summary of the Invention

[0007] The purpose of this invention is to provide a three-dimensional parameter intelligent detection end cap for fault monitoring of capacitive transformers. While maintaining standard fastening functions, the end cap incorporates a gas guiding path, a multi-stage Tesla rectification assembly, an in-situ multi-parameter monitoring chamber, a confluence diffusion zone, an elastic threshold pressure control chamber, and a lateral one-way discharge valve. This enables high-precision, high-response, and high-reliability condition monitoring and safe discharge without adding extra openings, breaking the original structure, or introducing leakage points.

[0008] The structure of this invention organically integrates fluid rectification technology, microcavity diffusion technology, and an elastic threshold control mechanism. It achieves high functionality through a compact, integrated structure, creating a bottom-up unidirectional flow path for gas within the device—from the inlet section to the rectification section, monitoring chamber, threshold chamber, and exhaust valve. This not only ensures real-time and effective monitoring data but also prevents backflow of external gas, ensuring long-term stable operation of the sensing elements.

[0009] The design principle of this invention is to integrate "fastening function + gas flow guidance function + multi-parameter monitoring function + anti-backflow function + threshold emission function" into one unit using the end cap as a carrier. By optimizing the shape of the internal cavity, laying out the micro Tesla structure, setting the diffusion transition zone, and mechanical matching of the elastic element, the high integration of industrial-grade safety monitoring components is achieved.

[0010] Compared with traditional technologies, this invention not only does not require changes to the equipment structure, but also has significant advantages such as fast response speed, high long-term stability, strong anti-pollution ability, and good installation compatibility. It is particularly suitable for application scenarios with extremely high requirements for airtightness, safety and reliability.

[0011] The three-dimensional parameter intelligent detection end cap for capacitive transformer fault monitoring described in this invention features a deeply optimized internal cavity design, enabling key functional units to achieve structural nesting, sealing isolation, and flow field continuity within a limited volume. The in-situ multi-parameter monitoring cavity, confluence and diffusion zone, multi-stage Tesla rectifier assembly, and elastic threshold pressure control cavity are all arranged around the central axis of the end cap, creating a continuous, stable, and irreversible unidirectional flow path for gas within the end cap. Through fluid dynamics optimization, the microscale flow field around the monitoring cavity is constantly updated, eliminating gas stagnation dead zones and significantly improving real-time response and detection accuracy to temperature, pressure, and specific gas components. Simultaneously, the sealing interfaces between multiple cavities are isolated by sealing grooves and sealing rings, giving the overall structure high-strength vibration resistance, high-reliability sealing performance, and long-term stable operation capability.

[0012] The first beneficial effect of this invention is that by integrating the multi-parameter monitoring structure, rectification structure, and emission structure into the end cap body, this device can directly replace the original ordinary end cap of the equipment without additional modification of the housing or addition of new holes, thus completing installation and deployment. This highly compatible implantable design enables in-situ detection of the internal state of the equipment without damaging the original sealing system, effectively avoiding the problems of long measurement time, cumbersome operation, and increased leakage risk caused by traditional disassembly-based detection methods, thereby significantly reducing maintenance costs and improving equipment operation safety and detection efficiency.

[0013] The second beneficial effect of this invention is that the constructed multi-stage Tesla rectifier assembly has significant unidirectional flow characteristics, allowing the gas inside the equipment to flow rapidly through the rectifier section and into the monitoring chamber under pressure differential, thereby shortening the response time of the monitoring element and making the detection data more representative of the actual operating conditions inside the equipment. Because the Tesla structure has high resistance in the reverse direction, it can effectively suppress the backflow of external pollutants such as air, dust, and water vapor into the monitoring chamber, ensuring that the internal gas environment is not affected by external disturbances and improving monitoring reliability. This design is particularly suitable for industrial scenarios that are susceptible to pollution, moisture, or sensitive to trace gas changes.

[0014] Furthermore, this invention, by incorporating an elastic threshold pressure control chamber and a lateral one-way discharge valve, enables the end cap to possess a pressure-triggered automatic discharge function. When the internal pressure or local gas accumulation reaches a set threshold, the threshold spring assembly is compressed and activates the lateral discharge path, allowing excess gas to be released promptly. Once the pressure returns to normal, the discharge valve automatically resets and re-establishes a seal. This structure not only prevents abnormal gas accumulation inside the equipment but also prevents reverse intrusion of external media, achieving a synergistic effect of pressure safety protection and gas monitoring, thereby further enhancing the overall system's safety and stability. Attached Figure Description

[0015] Figure 1 This is an overall front view of the three-element parameter intelligent detection end cover for fault monitoring of capacitive transformers according to the present invention. Figure 2 This is a right view of the three-element parameter intelligent detection end cover for fault monitoring of capacitive transformers according to the present invention. Figure 3 This is a longitudinal sectional view of the three-element parameter intelligent detection end cover for fault monitoring of capacitive transformers according to the present invention. Figure 4 This is a schematic diagram of the overall structure of the end cap of the present invention; Figure 5 This is a schematic diagram of the multi-stage Tesla rectifier component structure of the present invention; Figure 6 This is a schematic diagram of the in-situ multi-parameter monitoring cavity, elastic threshold pressure control cavity, and lateral unidirectional discharge structure of the present invention.

[0016] Components labeled in the diagram: 1. Hollow end cap body; 2. Axial flow guide channel; 3. Multi-stage Tesla rectifier assembly; 3-1. First asymmetric flow guide unit; 3-2. Second asymmetric flow guide unit; 3-3. Third asymmetric flow guide unit; 3-4. Fourth asymmetric flow guide unit; 4. Rectifier sealing ring groove; 5. In-situ multi-parameter monitoring chamber; 6. Temperature detection unit; 7. Pressure detection unit; 8. Hydrogen detection unit; 9. Elastic threshold pressure control chamber; 10. Threshold spring assembly; 11. Lateral one-way discharge valve; 12. Valve core; 13. Valve seat; 14. Reset spring; 15. Discharge guide hole; 16. Upper protective cover. Detailed Implementation

[0017] like Figures 1 to 6 As shown, the three-dimensional parameter intelligent detection end cover for fault monitoring of capacitive transformers of the present invention is generally divided axially from bottom to top into a bottom air inlet and guide section, a middle multi-stage rectification section, an upper monitoring and threshold control section, and an uppermost protective cover section. The hollow end cover body 1 serves as the mechanical shell of the load-bearing component and fluid channel, and its material is preferably 316 series stainless steel or other engineering alloys that meet the design strength and corrosion resistance requirements. The hollow structure ensures fastening performance, while the interior is precision-machined to form a smooth axial guide channel 2, reducing local resistance and turbulence generation, thereby providing stable inlet conditions for the multi-stage rectification assembly 3 and the subsequent monitoring chamber 5.

[0018] The geometry of the axial flow channel 2 (length, diameter, tapering or expanding sections, etc.) is optimized through fluid dynamics simulation to ensure appropriate sampling flow rate and pressure loss within the typical differential pressure range of the equipment. The size and distribution of the air inlets are determined by the on-site operating conditions. The orifice diameter cannot be too large to damage the sealing system, nor too small to cause sampling lag. Typically, multiple small-diameter air inlets arranged in parallel are used, along with filters or anti-clogging structures to prevent particles from entering the channel.

[0019] The multi-stage Tesla rectifier assembly 3 is located upstream of the axial guide channel 2 and consists of four asymmetric guide units 3-1 to 3-4 connected in series. Each unit employs a specific geometric combination of a reversing flow path, a diffusion-contraction section, and a bypass groove, resulting in a low-resistance flow field in the forward direction (from inside the device to the outside) and a high-resistance state in the reverse direction. The four-stage series connection, through the coupling of the stage number and the geometric parameters of each stage, significantly improves the rectification efficiency and suppresses backflow pulsation, thereby providing a continuous, stable, and "representative" gas sample for the monitoring chamber 5.

[0020] To ensure the sealing and fluid integrity of the rectifier assembly 3, a rectifier sealing ring groove 4 is provided on its outer circumference, which, together with a sealing ring (which can be a metal elastic ring or an elastic polymer ring), achieves circumferential airtightness. The rectifier assembly installation process requires a smooth surface (to avoid protrusions that could cause shearing or particle shedding), and precise control of geometric tolerances to avoid affecting the asymmetric flow guiding characteristics of the Tesla structure; during assembly, it should be ensured that the ring groove and the sealing ring are in uniform contact and anti-loosening measures should be taken.

[0021] The rectified gas enters the in-situ multi-parameter monitoring chamber 5. This chamber uses a confluence-diffusion structure to diffuse the localized fast flow from the rectifier section into a stable internal flow field, avoiding localized temperature or concentration measurement deviations caused by direct blowing. Temperature detection unit 6, pressure detection unit 7, and hydrogen detection unit 8 are arranged in validated positions within the chamber to ensure the representativeness of temperature and pressure sensing, as well as the representativeness of the gas composition probe sampling. Each detection unit should be designed with sensor specifications suitable for the industrial environment and undergo necessary mechanical protection and anti-contamination treatment, such as the addition of microporous filters, hydrophobic coatings, or mechanical mesh covers.

[0022] An elastic threshold pressure regulating chamber 9 is provided on the monitoring chamber 5, and a threshold spring assembly 10 is installed in this chamber. The spring stiffness, length, and preload of the threshold spring assembly 10 are determined through engineering calculations and experimental verification to find the trigger pressure point suitable for different devices. The structural design of the elastic threshold chamber 9 should ensure that when the triggering action occurs, the elastic element is compressed and generates a controlled displacement, opening the discharge channel connected to the lateral one-way discharge valve 11, without causing impact disturbance to the monitoring chamber 5 or damaging the sensor.

[0023] The lateral one-way discharge valve 11 consists of a valve core 12, a valve seat 13, and a return spring 14. Its operating principle is as follows: when the pressure in the threshold chamber 9 exceeds a preset value, the threshold spring assembly 10 causes gas to flow into the opening lateral channel and pushes the valve core 12 to overcome the initial force of the return spring 14, opening the valve seat 13. The gas is then discharged to the outside through the discharge guide hole 15. When the pressure drops below the threshold, the return spring 14 pushes the valve core 12 back to its original position, and the valve closes again to form a seal, preventing external gas from entering in reverse. The selection of valve body and sealing surface materials should consider corrosion resistance, wear resistance, and sealing reliability.

[0024] Installation and Usage Instructions: During installation, pre-assemble the upper protective cover 16, rectifier assembly 3, and monitoring chamber 5 onto the hollow end cap body 1, and confirm that the threshold spring assembly 10 and the side one-way discharge valve 11 are in factory calibration condition. Screw the hollow end cap body 1 into the original threaded hole of the equipment to the specified torque, and place and tighten the sealing ring (if designed) between the head and the contact surface of the equipment to ensure static sealing. During normal operation, the gas inside the equipment enters the monitoring chamber 5 through the axial guide channel 2 and rectifier assembly 3 under the pressure difference drive. The sensing unit continuously obtains representative samples and outputs monitoring signals (this patent does not involve the implementation of the signal transmission electronic unit); when the local or overall pressure exceeds the limit, the threshold chamber 9 and the side valve 11 work together to automatically complete the passive discharge, and the entire process does not require external energy intervention.

[0025] Maintenance and Calibration Recommendations: To ensure long-term reliability, it is recommended to develop a regular maintenance plan based on on-site operating conditions: First, regularly check the air inlet and axial guide channel 2 for blockages or particle accumulation, which can be addressed by purging or solvent cleaning; second, inspect the surface of the multi-stage Tesla rectifier assembly 3, and perform ultrasonic cleaning or replacement if necessary; third, regularly calibrate the spring stiffness and threshold operating point of the threshold spring assembly 10, and replace the spring if necessary to maintain emission threshold accuracy; fourth, perform a leak test on the sealing of the side one-way discharge valve 11 and replace worn seals; fifth, replace the protective cover or microporous filter of the detection unit in the monitoring chamber 5 to prevent sensor contamination. The above maintenance process does not require alteration of the main equipment structure and can be completed without disassembling the equipment for partial replacement or external maintenance.

[0026] The working process of this invention is as follows: The hollow end cap body 1 can directly replace the original end cap of the equipment and be screwed into the threaded hole of the housing. During installation, a reliable static seal is achieved through a pre-set head sealing ring. When the equipment is running, the internal medium enters from the bottom along the axial guide channel 2 under the action of pressure difference. It is then rectified step by step by the multi-stage Tesla rectifier assembly 3 through the four-stage asymmetric guide units 3-1 to 3-4 to obtain unidirectional low-resistance high-efficiency guide flow. The rectified airflow enters the in-situ multi-parameter monitoring chamber 5 through the confluence and diffusion zone, so that the temperature detection unit 6, pressure detection unit 7 and hydrogen detection unit 8 respectively obtain sample information reflecting the true internal state of the equipment. When the pressure in the monitoring chamber or threshold chamber rises and reaches the trigger value set by the threshold spring assembly 10, the spring action guides the gas into the lateral one-way discharge valve 11, and the excess gas is discharged to the outside through the discharge guide hole 15. When the pressure falls back, the reset spring 14 closes the valve core 12, and the system restores the seal, thereby achieving passive relief and self-protection against abnormal internal pressure without external energy.

[0027] The present invention features a compact and customizable structure: the stiffness of the threshold spring assembly 10, the geometric parameters of the rectifying units 3-1 to 3-4, the volume and sampling aperture of the monitoring chamber 5, and the dimensions of the discharge guide hole 15 can all be optimized according to the operating pressure, gas properties, and sensitivity requirements of the target equipment to adapt to different equipment and operating conditions. This modular design allows the present invention to be used in lightly loaded conventional pressure vessels as well as to be extended to complex systems with higher safety requirements.

[0028] The above description is only a few preferred embodiments of the present invention. Those skilled in the art can make equivalent substitutions or improvements to the implementation details such as material selection, geometric dimensions, connection methods, surface treatment processes, etc., without departing from the essence and spirit of the present invention, and all such substitutions or improvements fall within the protection scope of the present invention.

Claims

1. A three-element parameter intelligent detection end cover for monitoring the fault of a capacitive mutual inductor, characterized in that: The application relates to a hollow end cover body, an axial flow guide channel, a multi-stage Tesla rectifying assembly, an in-situ multi-parameter monitoring cavity, an elastic threshold pressure regulating cavity and a lateral one-way discharge valve; the hollow end cover body is internally provided with a through axial flow guide channel, a bottom gas inlet path for gas entering is formed at the bottom of the end cover, and the gas to be detected enters the end cover from the inside of the equipment; the multi-stage Tesla rectifying assembly is composed of a plurality of flow guide units in an asymmetric flow channel structure, including a first asymmetric flow guide unit, a second asymmetric flow guide unit, a third asymmetric flow guide unit and a fourth asymmetric flow guide unit, and is used for one-way rectifying the entering gas, so that the forward resistance is low and the reverse resistance is high. The in-situ multi-parameter monitoring cavity is arranged above the rectifying assembly, is internally provided with a temperature detection unit, a pressure detection unit and a hydrogen detection unit, and is used for in-situ multi-parameter detection of the rectified gas; the elastic threshold pressure regulating cavity is communicated with the monitoring cavity, is internally provided with a threshold spring assembly, and is used for generating elastic deformation and triggering a discharge action when the pressure in the monitoring cavity reaches a preset threshold value; the lateral one-way discharge valve is arranged on the side wall of the elastic threshold pressure regulating cavity, includes a valve core, a valve seat and a return spring, is used for opening a discharge channel when the internal pressure reaches the threshold value, discharging the gas through a discharge flow guide hole, and automatically closing and preventing external gas from flowing back after the pressure drops.

2. The three-element parameter intelligent detection end cover for monitoring the fault of a capacitive mutual inductor according to claim 1, characterized in that: The hollow end cover body is made of metal material, is internally provided with a threaded structure for fixation, and the axial flow guide channel is sealed, and is used for simultaneously accommodating the function structures of the flow guide channel and the monitoring cavity.

3. The three-element parameter intelligent detection end cover for monitoring the fault of a capacitive mutual inductor according to claim 1, characterized in that: The outlet end of the multi-stage Tesla rectifying assembly is provided with a rectifying sealing ring groove, which is used for guaranteeing the sealing property and the gas stability of the rectifying assembly before the gas enters the monitoring cavity.

4. The capacitance type mutual inductor fault monitoring three-element parameter intelligent detection end cover of claim 1, characterized in that: The internal structure of the in-situ multi-parameter monitoring cavity is optimized in a flow field, so that the temperature detection unit, the pressure detection unit and the hydrogen detection unit can detect in a stable sampling environment, and the monitoring precision is improved.

5. The capacitance type mutual inductor fault monitoring three-element parameter intelligent detection end cover according to claim 1, characterized in that: The threshold spring assembly is a compression spring structure, is used for forming a deformable elastic space in the elastic threshold pressure regulating cavity, and generates a control displacement when the internal pressure reaches the threshold value.

6. The capacitance type mutual inductor fault monitoring three-element parameter intelligent detection end cover according to claim 1, characterized in that: The lateral one-way discharge valve is used for making the valve core leave the valve seat and open the discharge flow guide hole when the internal pressure exceeds the threshold value, and is used for making the valve core press the valve seat by the return spring when the external pressure or the reverse pressure acts, so that the one-way discharge and the reverse blocking functions are realized.

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