High-cleanness gas protection management system and method based on digital twinning

Abstract

The invention discloses a high-cleanliness gas protection management system based on digital twinning, and relates to the technical field of digital management, and the system comprises a physical protection module which at least comprises a high-cleanliness micro-positive pressure protection unit; the data acquisition module is used for acquiring operation data related to high-cleanliness gas protection; the data storage and processing module is used for performing centralized storage, cleaning, statistics and preprocessing on the data acquired by the data acquisition module; the digital twin modeling module is used for constructing a digital twin model; the state evaluation and analysis module is used for evaluating the operation state of the physical protection module based on historical data and collected real-time data; and the risk identification and early warning module is used for carrying out identification and graded early warning on risks causing micro-positive pressure protection failure or environmental deterioration. According to the invention, by constructing the digital twinborn model, the originally dispersed high-cleanliness gas protection system is concentrated in a unified virtual space, and virtual-real integrated state monitoring and management are realized.

Description

Technical Field

[0001] This invention relates to the field of digital management technology, and in particular to a high-cleanliness gas protection management system and method based on digital twins. Background Technology

[0002] In industries such as coking, metallurgy, and mining, to improve the reliability and lifespan of critical equipment, high-cleanliness micro-positive pressure technology is increasingly being used to protect industrial enclosed spaces such as guide seals, headspaces of oil storage equipment, hydraulic stations, electrical rooms, and instrument rooms from dust, moisture, and corrosion. For example, micro-positive pressure air curtain dustproof devices are used for guide moving parts such as cylinder piston rods and motor shafts; headspace micro-positive pressure stabilizing devices are used for reducer oil tanks and hydraulic oil tanks; and micro-positive pressure protection systems using a mixture of fresh air and compressed air are employed in hydraulic stations and electrical rooms. These high-cleanliness gas protection systems involve multiple modules such as gas source treatment, micro-positive pressure control, multi-parameter monitoring, and intelligent adjustment, resulting in complex structures, numerous parameters, and dynamic changes in operating status depending on working conditions and the environment. In practical applications, the following problems exist: 1. The system status is not transparent. Specifically, the micro positive pressure protection system is distributed in multiple areas and involves multiple sets of equipment. The modules are interconnected, but there is a lack of a unified platform for overall visualization. It is difficult for operation and maintenance personnel to grasp the overall operating status and risk distribution of the system in a timely manner. 2. Data is scattered and difficult to use. Specifically, data such as pressure, flow rate, dew point, particulate matter concentration, and oil condition are scattered across different monitoring points and systems. There is a lack of centralized storage and unified analysis, making it difficult to perform trend analysis and fault prediction. Maintenance can only rely on experience. 3. Inability to provide proactive risk warning and decision support. Specifically, existing systems are mostly single-point alarms, which cannot conduct comprehensive risk assessment and warning at the system level. It is difficult to detect potential hazards such as "micro-positive pressure protection failure trend", filter blockage, and dryer failure in a timely manner, and it is even more impossible to provide quantitative decision-making basis for maintenance and renovation. 4. Lack of full lifecycle management supported by digital twins. Specifically, the construction and operation and maintenance of micro-positive pressure protection systems currently focus on physical equipment selection and parameter configuration, lacking a "virtual and physical integration" management system based on digital twins, resulting in insufficient system optimization and knowledge accumulation.

[0003] Therefore, it is necessary to construct a digital twin management system that maps high-cleanliness gas protection systems to digital space, enabling comprehensive modeling, visualization, and intelligent analysis of system structure, operating status, historical data, and risks, thereby improving the operational quality and management level of high-cleanliness gas protection systems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a high-cleanliness gas protection management system and method based on digital twin.

[0005] To solve the above technical problems, the technical solution of the present invention is as follows: A high-cleanliness gas protection management system based on digital twins includes: The physical protection module includes at least one high-cleanliness micro-positive pressure protection unit; The data acquisition module is used to collect operational data related to high-cleanliness gas protection. The data storage and processing module is used to centrally store, clean, statistically analyze, and preprocess the data collected by the data acquisition module. The digital twin modeling module is used to construct a digital twin model corresponding to the equipment information, pipeline connection relationship, spatial distribution information and control logic information based on the structural information and operating parameters of the physical protection module. The status assessment and analysis module is used to assess the operating status of the physical protection module based on historical data and collected real-time data. The risk identification and early warning module is used to identify and classify the risks that may lead to the failure of micro-positive pressure protection or environmental degradation based on preset rules and / or analysis models.

[0006] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, it further includes a visualization module for displaying the structural topology, operating status, parameter distribution, and risk information of the physical protection module on the digital twin interface.

[0007] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, it further includes an interface and integration module for exchanging data with a host computer or other digital twin platforms.

[0008] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, the high-cleanliness micro-positive pressure protection unit includes one or more of the following: a guided sealing micro-positive pressure air curtain dust prevention system, an oil storage equipment headspace micro-positive pressure protection system, and an industrial enclosed space micro-positive pressure protection system.

[0009] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, the data acquisition module includes sensors arranged in the main gas source pipe, each gas branch, the periphery of the protected object, and in industrial enclosed spaces. The sensors include at least one of pressure sensors, flow meters, temperature and humidity sensors, dew point sensors, particulate matter concentration sensors, and online oil condition monitoring devices.

[0010] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, the operating data related to high-cleanliness gas protection includes pressure, flow rate, temperature and humidity, dew point, particulate matter concentration, oil condition parameters, and equipment operating status information.

[0011] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, the status assessment and analysis module is configured to calculate evaluation indicators based on the collected operating data and generate corresponding status evaluation results. The evaluation indicators include one or more of the following: micro-positive pressure maintenance rate, gas source cleanliness level, filter element pressure difference trend, dryer load level, and oil contamination index.

[0012] As a preferred embodiment of the high-cleanliness gas protection management system based on digital twins described in this invention, the risk identification and early warning module is configured to: determine that there is a risk of high-cleanliness gas protection failure when the pressure is below the preset lower limit for more than a preset value, the dew point exceeds the preset upper limit, the particulate matter concentration is above the early warning value for more than a preset value, and / or the oil contamination index continues to rise, and generate early warning information according to the risk level.

[0013] This invention also provides a high-cleanliness gas protection management method based on digital twins, comprising: Acquire equipment information, pipeline connection relationships, spatial distribution information, and control logic information of the high-cleanliness micro-positive pressure protection unit, construct the corresponding digital twin model in the digital twin modeling module, and establish the mapping relationship between physical entities and virtual entities; The operating parameters of the high-cleanliness micro-positive pressure protection unit are collected by the data acquisition module, and the operating parameters are centrally stored and preprocessed by the data storage and processing module. The status assessment and analysis module evaluates the operating status of the high-cleanliness micro-positive pressure protection unit based on operating parameters and generates status evaluation results. The risk identification and early warning module identifies risks that could lead to the failure of high-cleanliness gas protection based on the status assessment results, preset rules and / or analysis models, and generates early warning information. The visualization module maps the status evaluation results and early warning information to the digital twin model, and displays them intuitively in the digital twin interface for operation and maintenance personnel to monitor and make decisions.

[0014] The beneficial effects of this invention are: (1) This invention constructs a digital twin model of equipment, pipelines, space and control logic, which concentrates the originally dispersed high-cleanliness gas protection system into a unified virtual space, thereby realizing the integrated virtual and real status monitoring and management.

[0015] (2) The present invention uses a visualization module to present pressure, flow rate, dew point, particulate matter concentration, oil status and equipment operating status in a graphical manner, which helps maintenance personnel to intuitively understand the system operating status and discover abnormal areas and weak links.

[0016] (3) The present invention utilizes the status assessment and analysis module and the risk identification and early warning module to identify the failure trend of micro positive pressure protection, filter and dryer load problems and environmental deterioration trend at the system level, and realize the transformation from "post-event treatment" to "pre-event prevention".

[0017] (4) This invention forms an experience knowledge base by analyzing historical data and event records, providing a quantitative basis for parameter setting, equipment selection and maintenance strategy optimization of micro positive pressure systems.

[0018] (5) This invention supports data interaction with the host computer, MES, DCS or other digital twin platforms in the factory through the interface and integration module, which is convenient to be incorporated into the enterprise's overall smart factory and intelligent operation and maintenance system. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A schematic diagram of the high-cleanliness gas protection management system based on digital twin provided by the present invention; Figure 2 This is a schematic diagram illustrating the mapping relationship between the physical protection subsystem and the digital twin model in this invention; Figure 3 This is a flowchart illustrating the data acquisition, processing, and status assessment process in this invention. Figure 4 This is a logical diagram illustrating the risk identification and early warning mechanism in this invention. Figure 5 This is a schematic diagram of the digital twin visualization interface in this invention. Detailed Implementation

[0021] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0022] Figure 1 This is a schematic diagram of a high-cleanliness gas protection management system based on digital twins, provided for this application. The system includes a physical protection subsystem, a data acquisition and processing layer, and a digital twin core and application layer.

[0023] Specifically, the physical protection subsystem is the physical protection module, which includes at least one high-cleanliness micro-positive pressure protection unit. This high-cleanliness micro-positive pressure protection unit includes one or more of the following: a guided-seal micro-positive pressure air curtain dust prevention system, an oil storage equipment headspace micro-positive pressure protection system, and an industrial confined space micro-positive pressure protection system.

[0024] The data acquisition and processing layer includes a data acquisition module and a data storage and processing module. The data acquisition module is connected to the physical protection module and is used to collect operational data related to high-cleanliness gas protection. This operational data includes at least one of the following: pressure, flow rate, temperature and humidity, dew point, particulate matter concentration, oil condition parameters, and equipment operating status information.

[0025] It should be noted that the data acquisition module includes sensors arranged in the main gas supply pipe, each gas branch, around the protected object, and in industrial enclosed spaces. The sensors include at least one of the following: pressure sensor, flow meter, temperature and humidity sensor, dew point sensor, particulate matter concentration sensor, and online oil condition monitoring device.

[0026] The data storage and processing module is used to centrally store, clean, statistically analyze, and preprocess the data collected by the data acquisition module, providing a data foundation for subsequent analysis and presentation.

[0027] The core and application layers of digital twins include a digital twin modeling module, a status assessment and analysis module, and a risk identification and early warning module. Among them, the digital twin modeling module is used to construct a digital twin model corresponding to equipment information, pipeline connection relationships, spatial distribution information, and control logic information based on the structural information and operating parameters of the physical protection module, forming a virtual system that maps one-to-one with the physical system.

[0028] The status assessment and analysis module is used to evaluate the operational status of the physical protection module based on historical data and collected real-time data. Specifically, this module is configured to calculate evaluation indicators based on the collected operational data and generate corresponding status assessment results. These evaluation indicators include one or more of the following: micro-positive pressure maintenance rate, air source cleanliness level, filter element pressure difference trend, dryer load level, and oil contamination index.

[0029] The risk identification and early warning module is used to identify and classify risks that may lead to the failure of the micro-positive pressure protection or environmental degradation, based on preset rules and / or analytical models, and to generate early warning information or recommended measures. The aforementioned risks that may lead to the failure of the micro-positive pressure protection or environmental degradation include filter clogging trends, dryer failure trends, and long-term low or high pressure trends. The analytical models are used to identify anomalies, predict trends, or calculate risk scores on the operating data of the high-cleanliness micro-positive pressure protection unit to assist in forming risk levels and handling recommendations. The analytical models include at least one or more of the following model types, and can be used in combination: trend / prediction models, anomaly detection models, risk scoring / classification models, correlation / consistency models, and mechanistic constraint models.

[0030] Preferably, the core and application layers of the digital twin also include a visualization module. This visualization module is used to display the structural topology, operating status, parameter distribution, and risk information of the physical protection module on the digital twin interface, and it supports multi-level display at the device level, region level, and system level.

[0031] Additionally, see Figure 1 The high-cleanliness gas protection management system based on digital twins also includes interface and integration modules, which are used to exchange data with the plant's host computer system, production management system or other digital twin platforms to achieve integration with existing automation and information systems.

[0032] This application also provides a high-cleanliness gas protection management method based on digital twins, which specifically includes the following steps: Step S101: Obtain the equipment information, pipeline connection relationship, spatial distribution information and control logic information of the high-cleanliness micro-positive pressure protection unit, construct the corresponding digital twin model in the digital twin modeling module, and establish the mapping relationship between physical entities and virtual entities; Step S102: The operating parameters of the high-cleanliness micro-positive pressure protection unit are collected through the data acquisition module, and the operating parameters are centrally stored and preprocessed through the data storage and processing module; Step S103: The status assessment and analysis module assesses the operating status of the high-cleanliness micro-positive pressure protection unit based on the operating parameters and generates status evaluation results; Step S104: The risk identification and early warning module identifies the risks that may lead to the failure of high-cleanliness gas protection based on the status evaluation results, preset rules and / or analysis models, and generates early warning information; Step S105: The visualization module maps the status evaluation results and early warning information to the digital twin model and displays them intuitively in the digital twin interface for operation and maintenance personnel to monitor and make decisions.

[0033] The above technical solution will be further explained below through specific embodiments.

[0034] Example 1: Protection System for Hydraulic Station and Electrical Room in a Coking Plant A coking plant has built a new hydraulic station room and an electrical room, both of which are relatively enclosed spaces. The rooms contain key equipment such as hydraulic stations, electrical cabinets, PLC control cabinets, and instrument panels.

[0035] 1. System Configuration Fresh air sampling ports are set up outside the factory area. The fresh air unit uses a 1.5 kW permanent magnet synchronous motor and is equipped with a servo controller. The fresh air filtration components include an F7 grade medium-efficiency filter and an H11 grade high-efficiency filter. The compressed air in the plant area is processed by a coarse filter, a fine filter and a dryer, and then output to the mixing and distribution module through a pressure reducing valve and a pressure regulating valve; Air supply vents are installed at the top of the hydraulic station room and electrical room, and return air vents are installed on the ground or at a low position to form a top-down airflow organization.

[0036] 2. Setting control targets The target for indoor-outdoor pressure difference is +80 Pa, and the allowable range is +50 to +120 Pa. The target for indoor particulate matter concentration is to be below a certain preset level (e.g., PM2.5 and PM10). The indoor relative humidity should be controlled between 40% and 70%.

[0037] 3. Operation process The intelligent control module automatically adjusts the speed of the fresh air unit based on the indoor and outdoor pressure difference, and activates compressed air compensation when the fresh air adjustment is insufficient. The multi-parameter monitoring module collects indoor and outdoor pressure, indoor temperature and humidity, and particulate matter concentration in real time, and transmits the data to the controller. The controller adjusts the mixing ratio and air volume according to environmental parameters to ensure that the indoor environment is within the target range.

[0038] 4. Performance After being put into operation, the pressure difference between indoors and outdoors has been basically stabilized at around +80 Pa. Dust inside the electrical room has been significantly reduced, and there is basically no visible dust accumulation on the surface of important electrical equipment. During the high humidity season, there is no obvious condensation indoors, and corrosion of the control cabinet has been significantly reduced.

[0039] Therefore, the technical solution of this application, by constructing a digital twin model of equipment, pipelines, space and control logic, concentrates the originally dispersed high-cleanliness gas protection system into a unified virtual space, realizes the integrated virtual and real status monitoring and management, and can identify the failure trend of micro-positive pressure protection, filter and dryer load problems and environmental degradation trends at the system level, realizing the transformation from "post-event treatment" to "pre-event prevention".

[0040] In addition to the above embodiments, the present invention may have other implementation methods; all technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A high-cleanliness gas protection management system based on digital twin, characterized in that: include: The physical protection module includes at least one high-cleanliness micro-positive pressure protection unit; The data acquisition module is used to collect operational data related to high-cleanliness gas protection. The data storage and processing module is used to centrally store, clean, statistically analyze, and preprocess the data collected by the data acquisition module. The digital twin modeling module is used to construct a digital twin model corresponding to the equipment information, pipeline connection relationship, spatial distribution information and control logic information based on the structural information and operating parameters of the physical protection module. The status assessment and analysis module is used to assess the operating status of the physical protection module based on historical data and collected real-time data. The risk identification and early warning module is used to identify and classify the risks that may lead to the failure of micro-positive pressure protection or environmental degradation based on preset rules and / or analysis models.

2. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: It also includes a visualization module, which is used to display the structural topology, operating status, parameter distribution and risk information of the physical protection module on the digital twin interface.

3. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: It also includes interfaces and integration modules for exchanging data with a host computer or other digital twin platforms.

4. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: The high-cleanliness micro-positive pressure protection unit includes one or more of the following: a guided sealing micro-positive pressure air curtain dust prevention system, an oil storage equipment headspace micro-positive pressure protection system, and an industrial enclosed space micro-positive pressure protection system.

5. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: The data acquisition module includes sensors arranged in the main gas supply pipe, each gas branch, around the protected object, and in industrial enclosed spaces. The sensors include at least one of the following: pressure sensor, flow meter, temperature and humidity sensor, dew point sensor, particulate matter concentration sensor, and online oil condition monitoring device.

6. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: The operational data related to high-cleanliness gas protection includes pressure, flow rate, temperature and humidity, dew point, particulate matter concentration, oil condition parameters, and equipment operating status information.

7. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: The status assessment and analysis module is configured to calculate evaluation indicators based on the collected operating data and generate corresponding status assessment results. The evaluation indicators include one or more of the following: micro-positive pressure maintenance rate, gas source cleanliness level, filter element pressure difference trend, dryer load level, and oil contamination index.

8. The high-cleanliness gas protection management system based on digital twin according to claim 1, characterized in that: The risk identification and early warning module is configured to: determine that there is a risk of high-cleanliness gas protection failure when the pressure is below the preset lower limit for more than a preset value, the dew point exceeds the preset upper limit, the particulate matter concentration is above the early warning value for more than a preset value, and / or the oil contamination index continues to rise, and generate early warning information according to the risk level.

9. A high-cleanliness gas protection management method based on digital twin, characterized in that: include: Acquire equipment information, pipeline connection relationships, spatial distribution information, and control logic information of the high-cleanliness micro-positive pressure protection unit, construct the corresponding digital twin model in the digital twin modeling module, and establish the mapping relationship between physical entities and virtual entities; The operating parameters of the high-cleanliness micro-positive pressure protection unit are collected by the data acquisition module, and the operating parameters are centrally stored and preprocessed by the data storage and processing module. The status assessment and analysis module evaluates the operating status of the high-cleanliness micro-positive pressure protection unit based on operating parameters and generates status evaluation results. The risk identification and early warning module identifies risks that could lead to the failure of high-cleanliness gas protection based on the status assessment results, preset rules and / or analysis models, and generates early warning information. The visualization module maps the status evaluation results and early warning information to the digital twin model, and displays them intuitively in the digital twin interface for operation and maintenance personnel to monitor and make decisions.

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