Boiler combustion performance test system

Abstract

The invention discloses a boiler combustion performance testing system, and relates to the technical field of boiler performance testing, and the system comprises a data collection module which collects test data in real time in a boiler combustion test process; the data transmission module receives the test data, forwards the test data through the wired communication link, and switches to the wireless communication link to forward the test data when identifying that the wired communication link has a fault; the data storage module stores the test data; and the data analysis and feedback module calls the test data stored in the data storage module, and performs deep analysis and analysis result feedback on the test data in combination with real-time monitoring, off-line analysis and report generation functions. Therefore, the system can realize real-time synchronous acquisition, automatic transmission, intelligent analysis and safe storage of test data, provides data support for boiler combustion performance optimization and fault diagnosis, and improves the test efficiency and test precision of boiler combustion performance.

Description

Boiler Combustion Performance Testing System Technical Field

[0001] This application relates to the field of boiler performance testing technology, and in particular to a boiler combustion performance testing system. Background Technology

[0002] Combustion performance testing is a core component in evaluating boiler thermal efficiency, pollutant emissions, and combustion stability during boiler research, development, production, and operation.

[0003] In related technologies, during the boiler combustion performance test, test data is collected manually or by a single sensor, and then statistically analyzed based on the average value to evaluate the boiler's combustion performance. This method has low test efficiency and poor accuracy. Summary of the Invention

[0004] This application aims to at least partially address one of the technical problems in the related art. Therefore, the purpose of this application is to propose a boiler combustion performance testing system that enables real-time synchronous acquisition, automated transmission, intelligent analysis, and secure storage of test data, providing data support for boiler combustion performance optimization and fault diagnosis, and improving the testing efficiency and accuracy of boiler combustion performance.

[0005] To achieve the above objectives, this application proposes a boiler combustion performance testing system, comprising: a data acquisition module configured to acquire test data in real time during boiler combustion testing; a data transmission module configured to receive test data, forward the test data via a wired communication link, and switch to a wireless communication link to forward the test data when a fault is detected in the wired communication link; a data storage module configured to receive and store the test data forwarded by the data transmission module; and a data analysis and feedback module configured to retrieve the test data stored in the data storage module, and perform in-depth analysis of the test data and provide feedback on the analysis results in conjunction with real-time monitoring, offline analysis, and report generation functions.

[0006] The boiler combustion performance testing system according to an embodiment of this application collects test data in real time during the boiler combustion test through a data acquisition module, receives the test data through a data transmission module, forwards the test data through a wired communication link, and switches to a wireless communication link to forward the test data when a fault is detected in the wired communication link. A data storage module receives and stores the test data forwarded by the data transmission module, and a data analysis and feedback module retrieves the test data stored in the data storage module. Combining real-time monitoring, offline analysis, and report generation functions, the system performs in-depth analysis of the test data and provides feedback on the analysis results. Therefore, this system can achieve real-time synchronous acquisition, automated transmission, intelligent analysis, and secure storage of test data, providing data support for boiler combustion performance optimization and fault diagnosis, and improving the testing efficiency and accuracy of boiler combustion performance.

[0007] In addition, the boiler combustion performance testing system according to the above embodiments of this application may also have the following additional technical features: According to one embodiment of this application, the data acquisition module includes: a sensor unit, which includes multiple sensors, configured to acquire boiler status data and combustion data to output corresponding sampling signals; a data conditioning unit, configured to receive the sampling signals and perform signal preprocessing on the sampling signals to generate corresponding digital signals; and a control unit, configured to perform signal aggregation and synchronization verification on the multiple digital signals output by the data conditioning unit, generate test data, send the test data to the data transmission module, and control the sensor unit to operate in response to the test data acquisition requirements.

[0008] According to one embodiment of this application, the plurality of sensors includes multiple of a furnace temperature sensor, a flue gas composition sensor, a fuel flow sensor, a steam pressure and temperature sensor, and a burner wind speed sensor.

[0009] According to one embodiment of this application, the data conditioning unit includes: a filtering subunit configured to filter the sampled signal; an amplification subunit configured to amplify the filtered sampled signal; and a conversion subunit configured to perform analog-to-digital conversion on the amplified sampled signal to generate a digital signal.

[0010] According to one embodiment of this application, the control unit is configured to perform signal aggregation and synchronization verification on multiple digital signals based on a preset acquisition period to generate test data, and to generate corresponding sensor acquisition instructions to drive the sensor to perform resampling when it is determined that there is a missing digital signal from the sensor or an abnormal acquisition time.

[0011] According to one embodiment of this application, the data transmission module includes: a wired communication unit, wherein a first communication terminal of the wired communication unit is connected to the output terminal of the data acquisition module, and a second communication terminal of the wired communication unit is connected to the wired communication terminal of the data storage module via an industrial switch, thereby establishing a wired communication link between the data transmission module and the data storage module; a wireless communication unit, wherein a first communication terminal of the wireless communication unit is connected to the output terminal of the data acquisition module, and a second communication terminal of the wireless communication unit is connected to the wireless communication terminal of the data transmission module via a wireless communication method, thereby establishing a wireless communication link between the data transmission module and the data storage module; and a communication switching unit configured to monitor the real-time communication status of the wired communication link, and, if a fault is determined in the wired communication link based on the real-time communication status, control the operation of the wireless communication link.

[0012] According to one embodiment of this application, the communication switching unit is configured to determine that the wired communication link has failed when it is determined that one or more of the following conditions are met: physical interruption of the wired communication link, packet loss rate exceeding a preset packet loss threshold, communication delay exceeding a preset time threshold, or communication error rate exceeding a preset error rate threshold for a continuous preset duration.

[0013] According to one embodiment of this application, the data transmission module includes: a communication protocol conversion unit, configured to identify a first communication protocol corresponding to the data sending end and a second communication protocol corresponding to the data receiving end, and when the first communication protocol and the second communication protocol are different, to perform protocol conversion on the output signal of the data sending end based on the second communication protocol, so as to send the output signal with completed protocol conversion to the data receiving end based on a wired communication link or a wireless communication link.

[0014] According to one embodiment of this application, the data storage module includes: a local storage unit, which adopts an industrial-grade SSD (Solid State Drive); a cloud storage unit, which is built on a network cloud service and supports off-site data backup, and is configured to classify and store the received test data according to the test number of the boiler combustion test and the timestamp of the test data; and a data management unit, which is configured to use MySQL database technology to create, query, back up and manage data indexes for the test data, and / or, upon receiving user instructions, identify user permissions and operate on the stored data in the local storage unit and the cloud storage unit based on user permissions and user instructions.

[0015] According to one embodiment of this application, the data analysis feedback module includes: a real-time monitoring unit configured to process and analyze test data in real time based on an edge computing and cloud analysis architecture to generate real-time data curves and trigger an audible and visual alarm when the test data exceeds a preset parameter threshold; an offline analysis unit configured to input test data into a pre-established correlation model between combustion parameters and boiler thermal efficiency and pollutant emissions based on a cloud server, and output boiler optimization suggestions; and a report generation unit configured to generate a test report based on the real-time data curves and boiler optimization suggestions, the test report including a test parameter record table, data analysis charts, and optimization suggestions. Attached Figure Description

[0016] Figure 1 is a connection diagram of the boiler combustion performance testing system according to an embodiment of this application; Figure 2 is an overall architecture block diagram of the boiler combustion performance testing system according to an embodiment of this application; Figure 3 is a flowchart of the workflow of the boiler combustion performance test data acquisition and analysis system according to an embodiment of this application. Detailed Implementation

[0017] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0018] The boiler combustion performance test data acquisition and analysis system proposed in this application is described below with reference to the accompanying drawings.

[0019] In the research, development, production, and operation and maintenance of boilers, combustion performance testing is a core step in evaluating boiler thermal efficiency, pollutant emissions, and combustion stability. Current industry practices for processing boiler combustion performance test data have the following problems: 1. They rely heavily on manual recording or single sensor data acquisition, failing to simultaneously acquire multi-dimensional data such as furnace temperature, flue gas composition (e.g., NOx, SO2), fuel flow rate, and steam parameters. This results in poor data timeliness and susceptibility to human error.

[0020] 2. Simply performing statistical analysis on the data, such as calculating average values, cannot establish a correlation model between combustion parameters and thermal efficiency and pollutant emissions, making it difficult to pinpoint the direction for combustion optimization.

[0021] 3. The inconsistent protocols of sensor data acquisition equipment from different manufacturers lead to the need for extensive customization and debugging when multiple devices work together, increasing testing costs and time.

[0022] 4. Most of the test data is stored on local servers, which are prone to data loss due to hardware failure or human operation. Furthermore, there is a lack of data backup and access control mechanisms, which cannot meet the requirements for test data traceability and compliance.

[0023] Therefore, there is an urgent need for a system with multi-source data collaborative acquisition, intelligent analysis, high compatibility and secure storage capabilities to solve the problems of low efficiency and insufficient analysis depth in existing boiler combustion performance testing technologies.

[0024] To address at least one of the aforementioned technical problems, this application proposes a boiler combustion performance testing system that enables real-time synchronous acquisition, automated transmission, intelligent analysis, and secure storage of test data. This provides data support for boiler combustion performance optimization and fault diagnosis, and improves the testing efficiency and accuracy of boiler combustion performance.

[0025] The boiler combustion performance testing system of this application embodiment is illustrated below with reference to the accompanying drawings.

[0026] Figure 1 is a connection diagram of a boiler combustion performance testing system according to an embodiment of this application.

[0027] As shown in Figure 1, the boiler combustion performance testing system of this application embodiment may include: a data acquisition module 10, a data transmission module 20, a data storage module 30, and a data analysis and feedback module 40.

[0028] The data acquisition module 10 is configured to acquire test data in real time during the boiler combustion test; the data transmission module 20 is configured to receive test data, forward the test data through a wired communication link, and switch to a wireless communication link to forward the test data when a fault is detected in the wired communication link; the data storage module 30 is configured to receive and store the test data forwarded by the data transmission module; and the data analysis and feedback module 40 is configured to retrieve the test data stored in the data storage module and, in conjunction with real-time monitoring, offline analysis, and report generation functions, perform in-depth analysis of the test data and provide feedback on the analysis results.

[0029] Specifically, the data acquisition module 10 is used to collect relevant parameter data in real time during the boiler combustion test, serving as test data. This may include parameters such as furnace temperature, flue gas composition, fuel flow rate, and steam pressure and temperature. The data transmission module 20 is used to forward the real-time acquired test data to the data storage module 30. The data transmission module 20 is connected to the data storage module 30 via both wired and wireless methods. Under normal conditions, wired data transmission uses a wired communication link. When an anomaly is detected in the valid communication link, the system switches to a wireless communication link to ensure the continuity and timeliness of data transmission.

[0030] The data storage module 30 is used to securely and stably store the received test data. It may include two storage units: local storage and cloud storage. The data analysis and feedback module 40 retrieves the stored data in the data storage module 30 and combines it with real-time monitoring, offline analysis, and report generation functions to achieve in-depth analysis and feedback of the test data. This enables real-time synchronous acquisition, automated transmission, intelligent analysis, and secure storage of test data, providing data support for boiler combustion performance optimization and fault diagnosis, and improving the testing efficiency and accuracy of boiler combustion performance.

[0031] Referring to Figures 2 and 3, in some embodiments of this application, the data acquisition module 10 includes: a sensor unit comprising multiple sensors, configured to acquire boiler status data and combustion data to output corresponding sampling signals; a data conditioning unit configured to receive the sampling signals and perform signal preprocessing on the sampling signals to generate corresponding digital signals; and a control unit configured to aggregate and synchronize the multiple digital signals output by the data conditioning unit, generate test data, send the test data to the data transmission module, and control the sensor unit to operate in response to test data acquisition requirements.

[0032] In some embodiments of this application, the multiple sensors include multiple of the following: furnace temperature sensor, flue gas composition sensor, fuel flow sensor, steam pressure and temperature sensor, and burner wind speed sensor.

[0033] In other words, the data acquisition module 10 is used to collect relevant parameter data in real time during the boiler combustion test. The sensor unit integrates a furnace temperature sensor, a flue gas composition sensor, a fuel flow sensor, a steam pressure and temperature sensor, and a burner wind speed sensor to comprehensively monitor the boiler combustion status and accurately acquire various combustion data. The data conditioning unit processes the analog signals output by the sensors and converts them into digital signals, providing high-quality raw data for subsequent data transmission and analysis. The control unit receives the digital signals, performs signal aggregation and synchronization verification to generate test data, which is then sent to the data transmission module 20. It also supports data acquisition at preset intervals and coordinates and synchronizes the operation of each sensor, such as controlling the start or stop of sensor operation.

[0034] In some embodiments of this application, the data conditioning unit includes: a filtering subunit configured to filter the sampled signal; an amplification subunit configured to amplify the filtered sampled signal; and a conversion subunit configured to perform analog-to-digital conversion on the amplified sampled signal to generate a digital signal.

[0035] In other words, the data conditioning unit sequentially filters, amplifies, and converts the analog signal output by the sensor, and then converts the processed analog signal into a digital signal, providing high-quality raw data for subsequent data transmission and analysis.

[0036] In some embodiments of this application, the control unit is configured to perform signal aggregation and synchronization verification on multiple digital signals based on a preset acquisition period to generate test data, and to generate corresponding sensor acquisition instructions to drive the sensor to perform resampling when it is determined that there is a missing digital signal from the sensor or an abnormal acquisition time.

[0037] Specifically, during the boiler combustion test, the sensor unit continuously collects analog signals of various parameters and transmits these signals to the data conditioning unit in real time. Following a preset procedure, the data conditioning unit first filters the analog signals to remove noise caused by environmental interference, then amplifies the filtered signals to ensure the signal strength meets the requirements for subsequent conversion. Finally, it converts the amplified analog signals into digital signals, marks the acquisition time on the digital signals, and transmits them to the control unit of the data acquisition module. After receiving the digital signals from each data conditioning unit, the control unit summarizes and synchronizes the data according to a preset acquisition cycle, confirming the consistency of the acquisition time of each sensor's data to avoid data deviations caused by sensor response delays. If any sensor data is missing or the acquisition time is abnormal, the control unit will resend the acquisition command to that sensor to ensure data integrity.

[0038] In some embodiments of this application, the data transmission module 20 includes: a wired communication unit, wherein a first communication terminal of the wired communication unit is connected to the output terminal of the data acquisition module, and a second communication terminal of the wired communication unit is connected to the wired communication terminal of the data storage module via an industrial switch, thereby establishing a wired communication link between the data transmission module and the data storage module; a wireless communication unit, wherein a first communication terminal of the wireless communication unit is connected to the output terminal of the data acquisition module, and a second communication terminal of the wireless communication unit is connected to the wireless communication terminal of the data transmission module based on a wireless communication method, thereby establishing a wireless communication link between the data transmission module and the data storage module; and a communication switching unit configured to monitor the real-time communication status of the wired communication link and, if it is determined based on the real-time communication status that the wired communication link has failed, control the operation of the wireless communication link.

[0039] In other words, the data transmission module 20 is used to transmit the collected test data in real time. The wired communication unit connects the data acquisition module and the data storage module via an industrial switch, supporting wired transmission. The wireless communication unit can use a cellular network module, Wi-Fi module, ZigBee module, etc., to support wireless transmission. Under normal conditions, data transmission is conducted through the wired communication link, while the wireless communication link is inactive. The communication switching unit monitors the wired communication link in real time. When a communication failure is detected in the wired communication link, the system switches to the wireless communication link for data transmission. Therefore, when a transmission failure occurs, the system can automatically switch to wireless transmission to ensure no data loss.

[0040] In some embodiments of this application, the communication switching unit is configured to determine that the wired communication link has failed when it is determined that one or more of the following conditions are met: physical interruption of the wired communication link, packet loss rate exceeding a preset packet loss threshold, communication delay exceeding a preset time threshold, or communication error rate exceeding a preset error rate threshold for a preset duration.

[0041] Specifically, after the control unit of the data acquisition module 10 completes data aggregation and verification, it transmits the test data to the data transmission module 20 via the RS485 interface. The data transmission module 20 prioritizes transmitting the data to the data storage module 30 via a wired link established by the industrial switch. The data transmission module 20 continuously monitors the communication status of the wired communication link in real time, and the monitoring indicators include signal strength, bit error rate, link delay, and packet loss rate. When any of the following fault conditions are detected in the wired communication link, the system immediately triggers an automatic switching mechanism: 1. Physical link interruption (e.g., network cable disconnection, switch port failure); 2. Continuous packet loss rate exceeds a preset threshold (e.g., 5%); 3. Communication delay exceeds a set time range (e.g., >500ms); 4. Signal interference causes a persistently high bit error rate.

[0042] Once any of the above conditions are met, the data transmission module 20 will automatically switch to wireless transmission mode (such as 4G / 5G or Wi-Fi backup link) in the next data transmission cycle to ensure that data is continuously and uninterruptedly transmitted to the data storage module 30.

[0043] In addition, during the communication link switching process, the data transmission module 20 automatically records the switching event and the reason, and can issue communication link switching prompts and wired communication link abnormality alerts through the system's monitoring interface. If the wired communication link is subsequently detected to have returned to normal and maintained stable operation for more than a set time (e.g., 30 seconds), the data transmission module 20 can automatically or manually switch back to wired transmission mode to reduce the long-term occupation cost of wireless transmission.

[0044] In some embodiments of this application, the data transmission module 20 further includes: a communication protocol conversion unit, configured to identify a first communication protocol corresponding to the data sending end and a second communication protocol corresponding to the data receiving end, and when the first communication protocol and the second communication protocol are different, to perform protocol conversion on the output signal of the data sending end based on the second communication protocol, so as to send the output signal with completed protocol conversion to the data receiving end based on a wired communication link or a wireless communication link.

[0045] In other words, the protocol conversion unit enables the testing system to be compatible with different types of sensors and devices, and achieves seamless integration with various sensors and devices through industrial protocol conversion.

[0046] Specifically, during data transmission, if protocol incompatibility issues arise with sensors or devices, the protocol conversion unit of the data transmission module 20 will automatically identify the protocol types of different devices and perform protocol conversion processing to achieve seamless connection between the data acquisition module and the data storage module, ensuring smooth data transmission.

[0047] In some embodiments of this application, the data storage module 30 includes: a local storage unit, which uses an industrial-grade SSD hard drive; a cloud storage unit, which is built on a network cloud service and supports off-site data backup, and is configured to classify and store the received test data according to the test number of the boiler combustion test and the timestamp of the test data; and a data management unit, which is configured to use MySQL database technology to create, query, back up and manage data indexes for the test data, and / or, upon receiving a user instruction, identify user permissions and operate on the stored data in the local storage unit and the cloud storage unit based on the user permissions and user instructions.

[0048] Specifically, the data storage module 30 is used to store test data securely and stably, and includes the following units: Local storage unit: adopts industrial-grade SSD hard disk to ensure efficient real-time writing of data and meet the requirements of long-term stable operation.

[0049] Cloud storage unit: Based on network cloud services, it supports off-site data backup. Data is categorized and stored using trial numbers and timestamps, ensuring high data security and supporting encryption to prevent data leakage.

[0050] Data Management Unit: Employs MySQL database technology for data indexing, querying, automatic backup and management, while supporting hierarchical user permissions to ensure system and data security and reliability.

[0051] For example, after receiving the test data sent by the data transmission module 20, the data storage module 30 first processes the data using the data management unit. Based on the preset test numbering rules during the test preparation phase, it assigns corresponding test numbers to the data and categorizes and labels the data based on the data collection timestamp. Subsequently, the data management unit synchronously writes the categorized complete data to both the local storage unit and the cloud storage unit, achieving real-time local storage and off-site backup. Simultaneously, the data management unit activates the query and automatic backup functions of the MySQL database, performing real-time indexing of the written data stream for convenient subsequent data retrieval. It also automatically backs up the data in local and cloud storage according to a preset period to prevent data loss due to hardware failure or network problems. Furthermore, the data management unit controls data access permissions based on user permission levels, allowing only authorized personnel to operate the data.

[0052] In some embodiments of this application, the data analysis feedback module 40 includes: a real-time monitoring unit configured to process and analyze test data in real time based on an edge computing and cloud analysis architecture to generate real-time data curves and trigger an audible and visual alarm when the test data exceeds a preset parameter threshold; an offline analysis unit configured to input test data into a pre-established correlation model between combustion parameters and boiler thermal efficiency and pollutant emissions based on a cloud server, and output boiler optimization suggestions; and a report generation unit configured to generate a test report based on the real-time data curves and boiler optimization suggestions, the test report including a test parameter record table, data analysis charts, and optimization suggestions.

[0053] In other words, the data analysis and feedback module 40 combines real-time monitoring, offline analysis, and report generation functions to achieve in-depth analysis and feedback of experimental data. Specifically, it includes the following modules: Real-time monitoring unit: Based on edge computing and cloud analysis architecture, it processes and analyzes data in real time. This unit can perform real-time verification while collecting data, generate real-time data curves, and trigger audible and visual alarms when parameters exceed preset thresholds, ensuring the safety and effectiveness of the combustion process.

[0054] Offline analysis unit: Based on a cloud server, it uses machine learning algorithms to establish a correlation model between combustion parameters and boiler thermal efficiency and pollutant emissions, and outputs optimization suggestions through data analysis to provide a scientific basis for subsequent combustion optimization.

[0055] Report generation unit: Automatically generates detailed test reports, including test parameter record tables, data analysis charts, optimization suggestions, etc., to facilitate subsequent decision-making and performance improvement.

[0056] For example, after the boiler combustion performance test is completed, the staff initiates an offline analysis command through the offline analysis unit of the data analysis feedback module. The offline analysis unit retrieves complete data from the data storage module, including data stored locally and backed up in the cloud, ensuring data integrity. Based on the computing power of the cloud server, machine learning algorithms are used to perform in-depth processing of the data. Specifically, by analyzing the changing patterns of parameters such as fuel flow rate, burner wind speed, and furnace temperature, a correlation model is established between these combustion parameters and boiler thermal efficiency and pollutant emissions. Then, the test data is used to reverse-engineer the model to identify key parameters affecting boiler combustion performance and output targeted combustion optimization suggestions, providing a scientific basis for subsequent boiler combustion optimization.

[0057] The offline analysis unit, after completing data analysis and outputting optimization suggestions, synchronously transmits the analysis results, real-time data curves during the experiment, and abnormal alarm records to the report generation unit of the data analysis feedback module. The report generation unit automatically integrates the above information according to a preset format to generate a complete experimental report containing experimental parameter record tables, data analysis charts, optimization suggestions, and other content. The data management unit of the data storage module archives all data from this experiment and updates the index information of the MySQL database to ensure that it can be quickly queried later. At the same time, the data management unit initiates a full backup, synchronously backing up the experimental data and archived information to the cloud storage unit to complete the long-term secure storage of the data.

[0058] As a specific embodiment of this application, and referring to Figures 1 and 3, the working process of the boiler combustion performance testing system is as follows: In actual use, the operator activates the parameter configuration function in the data analysis feedback module, and sets the basic parameters required for the test through this module, including the data acquisition cycle, the safety thresholds of each combustion parameter, and the test numbering rules. After these configuration information are processed by the protocol conversion unit of the data transmission module 20, they are synchronized to the control unit of the data acquisition module 10 through a wired transmission link, and simultaneously synchronized to the data management unit of the data storage module 30, laying the foundation for subsequent data classification, storage, and threshold verification. The control unit of the data acquisition module 10 sends a start command to the sensor unit, and the furnace temperature sensor, flue gas composition sensor, fuel flow sensor, steam pressure and temperature sensor, and burner wind speed sensor simultaneously enter the working state and begin to sense boiler combustion-related parameters in real time; the control unit simultaneously sends a signal to the data conditioning unit to activate its signal processing function, ensuring that the analog signals output by the sensors can be processed in a timely manner. The local storage unit and cloud storage unit of the data storage module 30 simultaneously enter the write-ready state, and the data management unit starts the indexing and backup function of the MySQL database, waiting to receive data.

[0059] During the boiler combustion test, the sensor unit continuously collects analog signals of various parameters and transmits them to the data conditioning unit in real time. Following a preset procedure, the data conditioning unit first filters the analog signals to remove noise caused by environmental interference, then amplifies the filtered signals to ensure the signal strength meets subsequent conversion requirements. Finally, it converts the amplified analog signals into digital signals, marks the acquisition time on the digital signals, and transmits them to the control unit of the data acquisition module. The control unit receives the digital signals from each data conditioning unit and summarizes and synchronizes the data according to a preset acquisition cycle. This confirms the consistency of the acquisition time of each sensor, avoiding data deviations caused by sensor response delays. If any sensor data is missing or the acquisition time is abnormal, the control unit will resend the acquisition command to that sensor to ensure data integrity.

[0060] After the control unit completes data aggregation and verification, it transmits the data to the data transmission module via the RS485 interface. The data transmission module prioritizes transmitting data to the data storage module via a wired link established by the industrial switch. The data transmission module continuously monitors the communication status of the wired link in real time, monitoring indicators including signal strength, bit error rate, link latency, and packet loss rate. When a communication failure is detected in the wired link, the data transmission module will automatically switch to wireless transmission mode (such as a 4G / 5G or Wi-Fi backup link) in the next data transmission cycle to ensure continuous and uninterrupted data transmission to the data storage module. During the switching process, the system records the switching event and the reason, and issues a prompt on the monitoring interface. If the wired link is subsequently detected to have returned to normal and maintained stable operation for more than a set time (such as 30 seconds), the system can automatically or manually switch back to wired transmission mode to reduce the long-term occupation cost of wireless transmission.

[0061] Meanwhile, if protocol incompatibility issues arise during data transmission, the protocol conversion unit of the data transmission module will automatically identify the protocol types of different devices and perform protocol conversion to achieve seamless connection between the data acquisition module and the data storage module, ensuring smooth data transmission.

[0062] After receiving the experimental data from the data transmission module, the data storage module first processes the data through the data management unit. Based on the pre-defined experimental numbering rules established during the experimental preparation phase, the data is assigned a corresponding experimental number and categorized using the data collection timestamp. Subsequently, the data management unit synchronously writes the categorized, complete data to both the local storage unit and the cloud storage unit, achieving real-time local storage and off-site backup. Simultaneously, the data management unit activates the query and automatic backup functions of the MySQL database, performing real-time indexing of the written data stream for easy subsequent data retrieval. It also automatically backs up the data in both local and cloud storage according to a preset period to prevent data loss due to hardware failure or network issues. Furthermore, the data management unit controls data access permissions based on user permission levels, allowing only authorized personnel to operate the data.

[0063] After the boiler combustion performance test is completed, staff initiate an offline analysis command through the offline analysis unit of the data analysis feedback module. The offline analysis unit retrieves complete data from the data storage module, including data stored locally and backed up in the cloud, ensuring data integrity. Based on the computing power of the cloud server, machine learning algorithms are used to perform in-depth data processing: by analyzing the changing patterns of parameters such as fuel flow rate, burner wind speed, and furnace temperature, a correlation model is established between these combustion parameters and boiler thermal efficiency and pollutant emissions. Then, the test data is used to reverse-engineer the model to identify key parameters affecting boiler combustion performance and output targeted combustion optimization suggestions, providing a scientific basis for subsequent boiler combustion optimization.

[0064] The offline analysis unit, after completing data analysis and outputting optimization suggestions, synchronously transmits the analysis results, real-time data curves during the experiment, and abnormal alarm records to the report generation unit of the data analysis feedback module. The report generation unit automatically integrates the above information according to a preset format to generate a complete experimental report containing experimental parameter record tables, data analysis charts, optimization suggestions, and other content. The data management unit of the data storage module archives all data from this experiment and updates the index information of the MySQL database to ensure that it can be quickly queried later. At the same time, the data management unit initiates a full backup, synchronously backing up the experimental data and archived information to the cloud storage unit to complete the long-term secure storage of the data.

[0065] The above embodiments achieve the following beneficial effects: 1. By integrating multiple types of combustion parameter sensors, key data for boiler combustion performance evaluation are comprehensively covered. The raw data quality is improved through filtering, amplification, and digital-to-analog conversion operations by the conditioning unit. Simultaneously, based on the control unit, synchronous sensor operation and periodic data acquisition are achieved. Time consistency verification and abnormal data acquisition provide dual protection for data accuracy and integrity. 2. Employing both wired and wireless transmission modes, combined with real-time link monitoring and automatic switching, avoids the risk of data loss from a single transmission method. The built-in protocol conversion unit automatically identifies and converts device protocols, achieving seamless integration with various sensors and devices, balancing transmission stability and system compatibility. 3. Relying on a dual architecture of local industrial-grade SSD and cloud storage, coupled with test number and timestamp-based classification management, real-time data writing and off-site backup are achieved. Based on MySQL database technology, the system achieves efficient data indexing, querying, and automatic backup, coupled with hierarchical user permission control, comprehensively ensuring data storage security and management reliability; 4. The real-time monitoring unit combines edge computing and cloud analysis to verify data in real time, generate curves, and trigger alarms when parameters exceed limits, ensuring the combustion process is safe and controllable. The offline analysis unit uses machine learning algorithms to establish a correlation model between combustion parameters, thermal efficiency, and pollutant emissions, accurately identifying key factors and outputting optimization suggestions, providing a scientific basis for combustion optimization; 5. The system forms a complete closed loop from parameter configuration, data acquisition, transmission, and storage to analysis feedback and report generation. The report generation unit can automatically integrate information to generate a complete test report. The collaborative linkage of various modules reduces manual intervention, thereby reducing manual processing costs and significantly improving the overall efficiency and reliability of boiler combustion performance testing.

[0066] In summary, the boiler combustion performance testing system according to the embodiments of this application acquires test data in real time during the boiler combustion test through a data acquisition module, receives the test data through a data transmission module, forwards the test data through a wired communication link, and switches to a wireless communication link to forward the test data when a fault is detected in the wired communication link. A data storage module receives and stores the test data forwarded by the data transmission module, and a data analysis and feedback module retrieves the test data stored in the data storage module. Combining real-time monitoring, offline analysis, and report generation functions, the system performs in-depth analysis of the test data and provides feedback on the analysis results. Therefore, this system can achieve real-time synchronous acquisition, automated transmission, intelligent analysis, and secure storage of test data, providing data support for boiler combustion performance optimization and fault diagnosis, and improving the testing efficiency and accuracy of boiler combustion performance.

[0067] It should be understood that various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented using 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.

[0068] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0069] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0070] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0071] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A boiler combustion performance testing system, characterized in that, include: The data acquisition module is configured to acquire test data in real time during the boiler combustion test; The data transmission module is configured to receive the test data, forward the test data via a wired communication link, and switch to a wireless communication link to forward the test data if a fault is detected in the wired communication link. The data storage module is configured to receive and store the test data forwarded by the data transmission module, and to store the test data. The data analysis feedback module is configured to retrieve the test data stored in the data storage module, and combine real-time monitoring, offline analysis and report generation functions to perform in-depth analysis of the test data and provide feedback on the analysis results.

2. The boiler combustion performance testing system according to claim 1, characterized in that, The data acquisition module includes: a sensor unit comprising multiple sensors configured to acquire boiler status data and combustion data to output corresponding sampling signals; a data conditioning unit configured to receive the sampling signals and perform signal preprocessing on the sampling signals to generate corresponding digital signals; and a control unit configured to aggregate and synchronize the multiple digital signals output by the data conditioning unit, generate the test data, send the test data to the data transmission module, and control the sensor unit to operate in response to test data acquisition requirements.

3. The boiler combustion performance testing system according to claim 2, characterized in that, The multiple sensors include multiple of the following: furnace temperature sensor, flue gas composition sensor, fuel flow sensor, steam pressure and temperature sensor, and burner wind speed sensor.

4. The combustion performance testing system according to claim 2, characterized in that, The data conditioning unit includes: a filtering subunit configured to filter the sampled signal; an amplification subunit configured to amplify the filtered sampled signal; and a conversion subunit configured to perform analog-to-digital conversion on the amplified sampled signal to generate the digital signal.

5. The combustion performance testing system according to claim 3, characterized in that, The control unit is configured to perform signal aggregation and synchronous verification on the multiple digital signals based on a preset acquisition period to generate the test data, and to generate corresponding sensor acquisition instructions to drive the sensor to perform resampling when it is determined that there is a missing digital signal from the sensor or an abnormal acquisition time.

6. The boiler combustion performance testing system according to claim 1, characterized in that, The data transmission module includes: a wired communication unit, wherein a first communication terminal of the wired communication unit is connected to the output terminal of the data acquisition module, and a second communication terminal of the wired communication unit is connected to the wired communication terminal of the data storage module via an industrial switch, thereby establishing a wired communication link between the data transmission module and the data storage module; a wireless communication unit, wherein a first communication terminal of the wireless communication unit is connected to the output terminal of the data acquisition module, and a second communication terminal of the wireless communication unit is connected to the wireless communication terminal of the data transmission module via wireless communication, thereby establishing a wireless communication link between the data transmission module and the data storage module; and a communication switching unit configured to monitor the real-time communication status of the wired communication link and, if a fault is determined in the wired communication link based on the real-time communication status, control the operation of the wireless communication link.

7. The boiler combustion performance testing system according to claim 6, characterized in that, The communication switching unit is configured to determine that the wired communication link has failed when it is determined that the wired communication link has one or more of the following conditions: physical interruption of the wired communication link, packet loss rate exceeding a preset packet loss threshold, communication delay exceeding a preset time threshold, or communication error rate exceeding a preset error rate threshold for a continuous preset duration.

8. The boiler combustion performance testing system according to claim 6, characterized in that, The data transmission module further includes a communication protocol conversion unit, configured to identify a first communication protocol corresponding to the data sending end and a second communication protocol corresponding to the data receiving end, and when the first communication protocol is different from the second communication protocol, to perform protocol conversion on the output signal of the data sending end based on the second communication protocol, so as to send the output signal with completed protocol conversion to the data receiving end based on the wired communication link or the wireless communication link.

9. The boiler combustion performance testing system according to claim 1, characterized in that, The data storage module includes: a local storage unit, which uses an industrial-grade SSD hard drive; a cloud storage unit, which is built on a network cloud service and supports off-site data backup, and is configured to classify and store the received test data according to the test number of the boiler combustion test and the timestamp of the test data; and a data management unit, which is configured to use MySQL database technology to create, query, back up and manage data indexes for the test data, and / or, upon receiving user instructions, identify user permissions and operate on the stored data in the local storage unit and the cloud storage unit based on the user permissions and the user instructions.

10. The boiler combustion performance testing system according to claim 1, characterized in that, The data analysis and feedback module includes: a real-time monitoring unit configured to process and analyze the test data in real time based on an edge computing and cloud analysis architecture to generate a real-time data curve and trigger an audible and visual alarm when the test data exceeds a preset parameter threshold; an offline analysis unit configured to input the test data into a pre-established correlation model between combustion parameters and boiler thermal efficiency and pollutant emissions based on a cloud server, and output boiler optimization suggestions; and a report generation unit configured to generate a test report based on the real-time data curve and the boiler optimization suggestions, the test report including a test parameter record table, data analysis charts, and optimization suggestions.

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