An anti-explosion engine air intake flame arrester system based on working condition self-adaption

Abstract

This invention relates to an explosion-proof engine intake flame arrester system based on adaptive operating conditions. The system includes a mechanical body module, a cleaning execution module, a multi-parameter status monitoring module, and a control and decision module. The control and decision module is configured to execute an adaptive cleaning control strategy, including: acquiring real-time differential pressure data from a differential pressure sensor and real-time operating parameters from the engine ECU, the real-time operating parameters including at least engine speed and load; determining whether the real-time differential pressure data exceeds a first preset differential pressure threshold and whether the real-time operating parameters are within a preset allowable cleaning operating condition range; if so, dynamically matching cleaning execution parameters according to the real-time operating parameters to generate a cleaning command; and controlling an explosion-proof solenoid valve to drive a pulse nozzle array to perform pulse jet cleaning of the flame arrester core according to the cleaning command. Through operating condition arbitration and dynamic parameter optimization, this system can reduce the impact of cleaning operations on the stability of engine power output while ensuring cleaning effectiveness.

Description

Technical Field

[0001] This invention relates to the field of engine safety technology, and in particular to an explosion-proof engine intake flame arrester system based on operating condition adaptation. Background Technology

[0002] In hazardous environments such as petroleum, chemical, and mining plants where explosive gases or dust are present, explosion-proof engines must be equipped with flame arresters in their intake systems to prevent backfire from igniting the external explosive atmosphere. Traditional flame arresters are mostly passive corrugated metal plate structures. Over long-term operation, dust, oil mist, and other pollutants in the air easily accumulate in the tiny channels of the flame arrester core, leading to increased intake resistance, reduced engine power, and increased fuel consumption. Therefore, the industry is attempting to introduce automatic cleaning technology to solve the clogging problem.

[0003] Several cleaning solutions for flame arresters have been proposed in the prior art. For example, patent CN219503375U discloses a flame arrester cleaning device that cleans by installing valve groups on pipes at both ends of the flame arrester and introducing replacement gas and cleaning fluid. However, this solution is complex and bulky, making it difficult to integrate into the compact space of an explosion-proof engine compartment; its cleaning process is time-consuming and cannot meet the needs of continuous engine operation; and the use of liquid cleaning poses a risk of residue, which may damage the engine. Patent CN121102819A proposes an intelligent self-cleaning flame arrester device that integrates cyclone separation, flame arrest, and self-cleaning functions, and automatically triggers multi-angle rotating jet cleaning based on a fixed pressure difference threshold. Although this technology achieves functional integration and automatic triggering, the cleaning triggering logic relies only on a single pressure difference threshold and does not consider the impact of high-pressure airflow injection on the engine's instantaneous intake airflow, air-fuel ratio, and output power, which may lead to engine instability.

[0004] In summary, existing technologies lack a solution that can deeply adapt to the dynamic operating characteristics of explosion-proof engines, ensuring efficient cleaning while minimizing interference with engine performance. Summary of the Invention

[0005] This invention provides an explosion-proof engine intake flame arrester system based on operating condition adaptation, in order to overcome at least one of the above-mentioned technical problems existing in the prior art.

[0006] To achieve the above objectives, the embodiments of the present invention adopt the following technical solutions: In a first aspect, the present invention provides an explosion-proof engine intake flame arrester system based on operating condition adaptive design, comprising: The mechanical body module includes an explosion-proof housing and a flame arrestor core disposed therein; The cleaning execution module includes an air source interface, an explosion-proof solenoid valve, and a pulse nozzle array connected in sequence. The air source interface is connected to the boost air source of the engine, and the pulse nozzle array is located upstream of the flame arrestor. The multi-parameter status monitoring module includes at least a differential pressure sensor that monitors the pressure difference before and after the flame arrester core; The control and decision-making module is electrically connected to the cleaning execution module and the multi-parameter status monitoring module, respectively, and is communicatively connected to the engine ECU. The control and decision module is configured to execute a condition-adaptive cleaning control strategy, which includes: The real-time differential pressure data of the differential pressure sensor and the real-time operating parameters of the engine ECU are acquired, wherein the real-time operating parameters include at least engine speed and load. Determine whether the real-time differential pressure data exceeds a first preset differential pressure threshold, and whether the real-time operating parameters are within a preset allowable cleaning operating range; If so, based on the real-time operating parameters, the cleaning execution parameters are dynamically matched to generate cleaning instructions; According to the cleaning command, the explosion-proof solenoid valve is controlled to drive the pulse nozzle array to perform pulse jet cleaning on the flame arrestor core.

[0007] In one possible implementation of the first aspect, the response time of the explosion-proof solenoid valve is less than 10 ms.

[0008] In one possible implementation of the first aspect, the pulse nozzle array is a ring-shaped Venturi pulse nozzle array.

[0009] In one possible implementation of the first aspect, the step of dynamically matching cleaning execution parameters and generating cleaning instructions based on the real-time operating condition parameters includes: Based on the real-time operating parameters, cleaning execution parameters that match the real-time operating parameters are found from a preset three-dimensional pulse spectrum. The cleaning execution parameters include pulse duration, pulse interval, and number of repetitions.

[0010] In one possible implementation of the first aspect, the multi-parameter status monitoring module further includes a temperature sensor for monitoring the temperature status of the flame arrester core; the control and decision module is further configured to execute a multi-dimensional safety early warning strategy, the multi-dimensional safety early warning strategy including: Acquire real-time temperature data from the temperature sensor; Based on the real-time temperature data and the real-time differential pressure data, it is determined whether there is a safety hazard in the flame arrestor core. If so, a safety warning is triggered.

[0011] In one possible implementation of the first aspect, determining whether the flame arrester core has a safety hazard based on the real-time temperature data and the real-time pressure difference data includes: Construct a pressure difference-temperature time-series correlation curve between the real-time temperature data and the real-time pressure difference data; Analyzing the pressure difference-temperature time-series correlation curve, when the real-time pressure difference data is within a preset normal pressure difference range and the real-time temperature data shows local abnormal temperature rise exceeding a preset temperature rise rate threshold, it indicates that the flame arrestor core has a potential risk of backfire; when the real-time pressure difference data is within a preset normal pressure difference range and the real-time temperature data shows uneven temperature distribution exceeding a preset uneven temperature distribution threshold, it indicates that the flame arrestor core has a risk of local hot spots; when the real-time pressure difference abnormally increases and exceeds a second preset pressure difference threshold but the real-time temperature data is within a preset normal temperature range, it indicates that the flame arrestor core has a risk of physical blockage.

[0012] In one possible implementation of the first aspect, the control and decision module is further configured to execute a predictive maintenance method based on weighted equivalent runtime, the predictive maintenance method comprising: The weighted equivalent runtime model is constructed as shown in the following formula: WEOT=∑[t i ×w(load) i )×k(Env i )]; Among them, t i For the runtime segment, w(load) i ) represents the weighting coefficient of the average engine load during time period i, and k(Env) represents the weighting coefficient of the average engine load during time period i. i () represents a correction factor based on environmental parameters; The load data of the engine ECU is recorded in real time, and the WEOT value is calculated cumulatively. The remaining service life of the flame arrestor core is dynamically predicted based on the WEOT value.

[0013] In one possible implementation of the first aspect, the predictive maintenance method further includes: Record the pressure difference change before and after each cleaning event, and correlate it with the average load data and average environmental parameters within the corresponding cleaning cycle of the cleaning event; The weighting coefficients and the correction coefficients are adaptively adjusted using the recursive least squares method to make the weighted equivalent running time model fit the actual pollution accumulation characteristics.

[0014] In one possible implementation of the first aspect, the multi-parameter status monitoring module further includes an intake air quality sensor for detecting dust concentration and / or humidity in the intake air, using the detection data from the intake air quality sensor as input to the correction coefficient.

[0015] In one possible implementation of the first aspect, dynamically predicting the remaining service life of the flame arrester core based on the WEOT value includes: Determine whether the remaining service life of the flame arrestor core is less than a preset service life alarm threshold. If so, generate and push a predictive maintenance prompt message.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: The present invention provides an explosion-proof engine intake flame arrester system based on operating condition adaptation. Through operating condition arbitration and dynamic parameter optimization, it can greatly reduce the impact of cleaning operation on the stability of engine power output while ensuring the cleaning effect.

[0017] Furthermore, the present invention provides an explosion-proof engine intake flame arrester system based on operating condition adaptation, which utilizes the engine's own air source to achieve a self-closed loop system; the integrated and compact design facilitates direct replacement of existing flame arresters and has strong applicability.

[0018] Secondly, the present invention provides a condition-adaptive health management method for explosion-proof engine intake flame arresters, applicable to any of the condition-adaptive explosion-proof engine intake flame arrester systems described in the first aspect, wherein the health management method includes: Acquire real-time differential pressure data, real-time temperature data, and real-time operating parameters of the engine for the flame arrester core; Determine whether the real-time differential pressure data exceeds a first preset differential pressure threshold and whether the real-time operating parameters are within the allowable cleaning range; if so, dynamically match the cleaning execution parameters according to the real-time operating parameters and generate a cleaning command; according to the cleaning command, control the explosion-proof solenoid valve to drive the pulse nozzle array to perform pulse jet cleaning on the flame arrestor core; Based on the real-time temperature data and the real-time pressure difference data, determine whether there is a safety hazard in the flame arrestor core; if so, trigger a safety warning. Furthermore, based on the weighted equivalent operating time (WEOT) model, the remaining service life of the flame arrester core is predicted, and when the remaining service life of the flame arrester core is less than a preset life alarm threshold, a predictive maintenance prompt message is generated and pushed.

[0019] Thirdly, the present invention provides an electronic device comprising: at least one processor and at least one memory, wherein the memory stores computer-readable instructions; the computer-readable instructions are executed by one or more of the processors, causing the electronic device to implement a knowledge recommendation method based on the research and development process as in any implementation of the second aspect.

[0020] Fourthly, the present invention provides a storage medium having a computer-executable program stored thereon, the computer-executable program being used to cause a computer to execute a knowledge recommendation method based on the research and development process as in any implementation of the second aspect.

[0021] Understandably, the beneficial effects of the second aspect method, the third aspect electronic device, and the fourth aspect storage medium provided above can be referenced to the beneficial effects of the first aspect and any of its possible design embodiments, which will not be repeated here. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 A structural block diagram of an explosion-proof engine intake flame arrester system based on operating condition adaptation provided in an embodiment of the present invention; Figure 2 This is a flowchart illustrating the working condition adaptive cleaning control strategy in an embodiment of the present invention. Figure 3 This is a flowchart illustrating the multi-dimensional security early warning strategy in an embodiment of the present invention; Figure 4 This is a flowchart illustrating the predictive maintenance method in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present invention. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be described below with reference to the accompanying drawings. In the description of the present invention, unless otherwise stated, " / " indicates that the objects before and after are in an "or" relationship. For example, A / B can represent A or B. The "or" in the present invention is merely a description of the relationship between the related objects, indicating that three relationships can exist. For example, A or B can represent: A alone, A and B simultaneously, and B alone. A and B can be singular or plural. Furthermore, in the description of the present invention, unless otherwise stated, "multiple" refers to two or more. "At least one of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items.

[0025] Furthermore, to facilitate a clear description of the technical solutions of the embodiments of the present invention, the terms "first" and "second" are used in the embodiments of the present invention to distinguish identical or similar items with essentially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0026] In this embodiment of the invention, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" or "for example" in this embodiment of the invention should not be construed as superior or more advantageous than other embodiments or designs. Specifically, the use of terms such as "exemplary" or "for example" is intended to present the relevant concepts in a concrete manner for ease of understanding.

[0027] In hazardous environments such as petroleum, chemical, and mining plants where explosive gases or dust are present, explosion-proof engines must be equipped with flame arresters in their intake systems to prevent backfire from igniting the external explosive atmosphere. Traditional flame arresters are mostly passive corrugated metal plate structures. Over long-term operation, dust, oil mist, and other pollutants in the air easily accumulate in the tiny channels of the flame arrester core, leading to increased intake resistance, reduced engine power, and increased fuel consumption. Therefore, the industry is attempting to introduce automatic cleaning technology to solve the clogging problem.

[0028] Several cleaning solutions for flame arresters have been proposed in the prior art. For example, patent CN219503375U discloses a flame arrester cleaning device that cleans by installing valve groups on pipes at both ends of the flame arrester and introducing replacement gas and cleaning fluid. However, this solution is complex and bulky, making it difficult to integrate into the compact space of an explosion-proof engine compartment; its cleaning process is time-consuming and cannot meet the needs of continuous engine operation; and the use of liquid cleaning poses a risk of residue, which may damage the engine. Patent CN121102819A proposes an intelligent self-cleaning flame arrester device that integrates cyclone separation, flame arrest, and self-cleaning functions, and automatically triggers multi-angle rotating jet cleaning based on a fixed pressure difference threshold. Although this technology achieves functional integration and automatic triggering, the cleaning triggering logic relies only on a single pressure difference threshold and does not consider the impact of high-pressure airflow injection on the engine's instantaneous intake airflow, air-fuel ratio, and output power, which may lead to engine instability.

[0029] In view of this, on the one hand, embodiments of the present invention provide an explosion-proof engine intake flame arrester system based on operating condition adaptation, comprising: a mechanical body module, including an explosion-proof housing and a flame arrester core disposed therein; a cleaning execution module, including a gas source interface, an explosion-proof solenoid valve and a pulse nozzle array connected in sequence, wherein the gas source interface is connected to the engine's boost gas source, and the pulse nozzle array is disposed upstream of the flame arrester core; a multi-parameter status monitoring module, including at least a differential pressure sensor for monitoring the pressure difference across the flame arrester core; and a control and decision module, electrically connected to the cleaning execution module and the multi-parameter status monitoring module respectively, and communicatively connected to the engine ECU; In this configuration, the control and decision module is configured to execute an adaptive cleaning control strategy, which includes: acquiring real-time differential pressure data from the differential pressure sensor and real-time operating parameters from the engine ECU, wherein the real-time operating parameters include at least engine speed and load; determining whether the real-time differential pressure data exceeds a first preset differential pressure threshold and whether the real-time operating parameters are within a preset allowable cleaning operating range; if so, dynamically matching cleaning execution parameters according to the real-time operating parameters to generate a cleaning command; and controlling the explosion-proof solenoid valve to drive the pulse nozzle array to perform pulse jet cleaning on the flame arrester core according to the cleaning command.

[0030] The present invention provides an explosion-proof engine intake flame arrester system based on operating condition adaptation. Through operating condition arbitration and dynamic parameter optimization, it can greatly reduce the impact of cleaning operation on the stability of engine power output while ensuring the cleaning effect. In addition, it utilizes the engine's own air source to achieve a self-closed loop system. The integrated and compact design makes it easy to directly replace existing flame arresters and has strong applicability.

[0031] The following description, in conjunction with the accompanying drawings, illustrates an explosion-proof engine intake flame arrester system based on operating condition adaptation provided by an embodiment of the present invention.

[0032] like Figure 1 As shown, this embodiment of the invention provides a condition-adaptive explosion-proof engine intake flame arrester system, which may include, but is not limited to: Mechanical body module 110 includes an explosion-proof housing and a flame arrestor core disposed therein; The cleaning execution module 120 includes an air source interface, an explosion-proof solenoid valve, and a pulse nozzle array connected in sequence. The air source interface is connected to the boost air source of the engine, and the pulse nozzle array is located upstream of the flame arrestor. The multi-parameter status monitoring module 130 includes at least a differential pressure sensor that monitors the pressure difference before and after the flame arrester core; The control and decision module 140 is electrically connected to the cleaning execution module 120 and the multi-parameter status monitoring module 130, respectively, and is communicatively connected to the engine ECU 150.

[0033] It should be noted that the explosion-proof housing in the embodiments of the present invention may be, but is not limited to, an explosion-proof cast aluminum housing, as long as it meets the Ex d IIB T4 Gb explosion-proof rating. The flame arrestor core in the embodiments of the present invention may be, but is not limited to, a metal corrugated plate flame arrestor core, and is not limited here.

[0034] Furthermore, it should be noted that all sensors, solenoid valves, nozzles, and controller interfaces involved in the embodiments of the present invention adopt explosion-proof design in accordance with GB 3836 standard (Ex d IIB T4 Gb), and are integrated and compactly laid out with the flame arrester housing. The specific model is selected according to actual needs and is not limited here.

[0035] In specific implementation, the air source interface in this embodiment of the invention is directly connected to the clean air pipeline after the engine turbocharger. The air source pressure is between 0.6-0.8MPa. No external air compressor is required. The system is self-closed-loop, which can greatly improve the reliability of the air source.

[0036] In specific implementation, the explosion-proof solenoid valve in the embodiments of the present invention is preferably an explosion-proof high-speed solenoid valve. The response time of the explosion-proof high-speed solenoid valve is less than 10ms. The use of the explosion-proof high-speed solenoid valve can ensure accurate pulse start and stop and eliminate airflow tailing and delay.

[0037] In specific implementation, the pulse nozzle array in the embodiments of the present invention is preferably a ring Venturi pulse nozzle array.

[0038] This invention employs an annular Venturi pulse nozzle. The rapid opening and closing of the explosion-proof solenoid valve generates a high-intensity, short-duration (0.1-0.3 seconds) pulse airflow. Utilizing the Venturi effect, a local high-speed, low-pressure zone is formed at the outlet, enhancing the airflow's ability to strip and entrain contaminants. Simultaneously, the annular layout achieves full coverage of the flame arrestor core surface, improving the cleaning efficiency of the flame arrestor core while reducing air consumption, reducing continuous interference with the main airflow, and thus minimizing the impact of the cleaning process on the engine's output stability.

[0039] In specific implementation, the control and decision module 140 in this embodiment of the invention is configured to execute a condition-adaptive cleaning control strategy, such as... Figure 2 As shown, the adaptive cleaning control strategy includes: S11: Obtain the real-time differential pressure data from the differential pressure sensor and the real-time operating parameters of the engine ECU150, wherein the real-time operating parameters include at least the engine speed and load.

[0040] In specific implementation, the control and decision-making module 140 in this embodiment of the invention can be a controller with data processing capabilities, such as a microcomputer or a single-chip microcomputer, and is not limited here.

[0041] S12: Determine whether the real-time differential pressure data exceeds the first preset differential pressure threshold and whether the real-time operating parameters are within the preset allowable cleaning operating range.

[0042] In specific implementation, the first preset differential pressure threshold in the embodiments of the present invention is set according to actual needs, such as the type and material of the flame arrester core (the differential pressure threshold of the metal corrugated plate flame arrester core can be set to 1.5 kPa), and is not limited here.

[0043] In specific implementation, the preset allowable cleaning condition range in the embodiments of the present invention may be, but is not limited to, idling (e.g., speed ≤ 1000 rpm) or low load stable condition (e.g., load ≤ 30%). When the engine speed is ≤ 1000 rpm or the load is ≤ 30%, it indicates that the engine is within the allowable cleaning condition range, and the flame arrester core can be cleaned at this time.

[0044] S13: Based on the real-time operating parameters, dynamically match the cleaning execution parameters and generate cleaning instructions.

[0045] In one feasible implementation, the step of dynamically matching cleaning execution parameters and generating cleaning instructions based on the real-time operating parameters in this embodiment of the invention may include, but is not limited to: Based on the real-time operating parameters, cleaning execution parameters that match the real-time operating parameters are found from a preset three-dimensional pulse spectrum. The cleaning execution parameters include pulse duration, pulse interval, and number of repetitions.

[0046] In specific implementation, the three-dimensional pulse spectrum diagram in this embodiment of the invention is the core data model for realizing adaptive cleaning control under working conditions. Its essence can be understood as a pre-calibrated three-dimensional lookup table or function mapping relationship. The three dimensions of the three-dimensional pulse spectrum diagram are: X-axis: Real-time intake airflow (or a highly relevant parameter such as boost pressure); Y-axis: Engine load percentage; Z-axis: Cleaning parameters (such as solenoid valve pulse duration, pulse interval time, and number of repetitions).

[0047] The three-dimensional pulse spectrum is constructed based on engine bench test data or CFD flow field simulation, and the optimal balance point between cleaning effect and disturbance performance at each operating point is determined through system calibration. The constructed three-dimensional pulse spectrum is embedded in the control and decision module 140 in the form of a table or fitting function.

[0048] S14: According to the cleaning command, control the explosion-proof solenoid valve to drive the pulse nozzle array to perform pulse jet cleaning on the flame arrestor core.

[0049] The embodiments of the present invention, through operating condition arbitration and dynamic parameter optimization, can minimize the impact of cleaning operations on the stability of engine power output while ensuring the cleaning effect.

[0050] In one feasible implementation, the multi-parameter status monitoring module 130 in this embodiment of the invention further includes a temperature sensor for monitoring the temperature status of the flame arrester core; the control and decision module 104 is also configured to execute a multi-dimensional safety early warning strategy, such as... Figure 3 As shown, the multi-dimensional security early warning strategy includes: S21: Obtain the real-time temperature data from the temperature sensor; S22: Based on the real-time temperature data and the real-time pressure difference data, determine whether there is a safety hazard in the flame arrestor core. If so, trigger a safety warning.

[0051] In one feasible implementation, the step of determining whether the flame arrestor core has a safety hazard based on the real-time temperature data and the real-time pressure difference data in this embodiment of the invention may include, but is not limited to: Construct a pressure difference-temperature time-series correlation curve between the real-time temperature data and the real-time pressure difference data; Analyzing the pressure difference-temperature time-series correlation curve, when the real-time pressure difference data is within a preset normal pressure difference range and the real-time temperature data shows local abnormal temperature rise exceeding a preset temperature rise rate threshold, it indicates that the flame arrestor core has a potential risk of backfire; when the real-time pressure difference data is within a preset normal pressure difference range and the real-time temperature data shows uneven temperature distribution exceeding a preset uneven temperature distribution threshold, it indicates that the flame arrestor core has a risk of local hot spots; when the real-time pressure difference abnormally increases and exceeds a second preset pressure difference threshold and the real-time temperature data is within a preset normal temperature range, it indicates that the flame arrestor core has a risk of physical blockage.

[0052] In specific implementation, this embodiment of the invention provides multiple temperature sensors in the explosion-proof housing to monitor the temperature at different locations of the flame arrestor core. The localized abnormal surge in this embodiment refers to a sharp, non-linear jump in the temperature value measured by one of the temperature sensors within a very short time (e.g., milliseconds or seconds), for example, a measured temperature rise rate greater than 10℃ / s, exceeding a preset temperature rise rate threshold (e.g., 5℃ / s), indicating a potential risk of backfire in the flame arrestor core. The uneven temperature distribution in this embodiment refers to a significant difference in temperature between multiple temperature sensors at the same time, exceeding the normal range, for example, a difference of 10℃ between the highest and lowest temperatures, significantly greater than a preset uneven temperature distribution threshold (e.g., 5℃), indicating a risk of localized hot spots in the flame arrestor core. In this embodiment, the second preset differential pressure threshold is greater than the first preset differential pressure threshold. For example, if the first preset differential pressure threshold is 1.5 kPa, then the second preset differential pressure threshold can be set to 2.0 kPa or 2.5 kPa, without limitation.

[0053] In the specific implementation process, when the potential backfire risk, the local hotspot risk, or the physical congestion risk occurs, the embodiments of the present invention can issue early warning information through a preset security early warning strategy. For example, when there is a potential backfire risk, an early warning information is sent to the operation and maintenance terminal. The early warning information includes the risk category, the discovery time, and risk handling suggestions, etc., which are not limited here.

[0054] This invention establishes and analyzes a pressure differential-temperature time-series correlation curve, enabling dual and cross-warning of physical blockage and early thermal failure. This allows for more accurate identification of the flame arrester's status and avoids over- or under-maintenance.

[0055] In one feasible implementation, the control and decision module 140 in this embodiment of the invention is further configured to execute a predictive maintenance method based on weighted equivalent runtime, such as... Figure 4 As shown, the predictive maintenance method includes: S31: Construct a weighted equivalent runtime model, as shown in the following formula: WEOT=∑[t i ×w(load) i )×k(Env i )]; Among them, t i For the runtime segment, w(load) i ) represents the weighting coefficient of the average engine load during time period i, and k(Env) represents the weighting coefficient of the average engine load during time period i. i () represents a correction factor based on environmental parameters; S32: Record the load data of the engine ECU in real time and calculate the WEOT value cumulatively; S33: Dynamically predict the remaining service life of the flame arrestor core based on the WEOT value.

[0056] In the specific implementation process, the blockage and aging of the flame arrestor core are mainly affected by three factors: (1) Time (t): The longer it runs, the more dust accumulates.

[0057] (2) Engine load: The greater the load, the greater the intake flow and pulse pressure, the stronger the impact force of the dust it carries, and the faster the blockage and wear.

[0058] (3) Environmental severity (Env): The higher the concentration of dust and the greater the humidity, the faster the blockage.

[0059] The weighted equivalent runtime model constructed in this embodiment of the invention can be specifically understood as follows: WEOT = Actual lifespan consumed = Σ (a certain period of time × the level of hardship during that period × the severity of the environment during that period) For example, suppose the daily work of a certain explosion-proof diesel engine is divided into two segments: Morning (t=4 hours): Idle and test in a clean warehouse (low load, w=1; clean environment, k=1).

[0060] The WEOT contribution is 4 × 1 × 1 = 4 hours.

[0061] Afternoon (t=4 hours): Heavy load uphill in the coal mine (high load, w=5; high dust, k=2).

[0062] The WEOT contributed is 4 × 5 × 2 = 40 hours.

[0063] Total for one day: Actual clock time: 8 hours.

[0064] Equivalent Wear Time (WEOT): 4 + 40 = 44 hours.

[0065] In specific implementation, the method of dynamically predicting the remaining service life of the flame arrestor core based on the WEOT value in this embodiment of the invention can be understood as follows: The manufacturer determined through experiments that a certain flame arrestor core, under "standard operating conditions" (w=1, k=1), can only withstand a maximum of 1000 hours of cumulative contamination before becoming clogged (requiring maintenance). This 1000 hours is the total WEOT range.

[0066] The control and decision module calculates t every second. i ×w i ×k i And these are added together. For example, the equipment actually ran for 100 hours, but through the above weighted calculation, the accumulated ∑WEOT has reached 300 hours.

[0067] Then, calculate the remaining lifetime (RUL) using the following formula: RUL = (Total Lifetime Threshold - Cumulative WEOT) / Current Average Degradation Rate For example, the equipment has actually run for 200 hours, but based on load and environmental weighting, the equivalent contamination life of the flame arrester core has already consumed 500 hours. The total designed WEOT life is 1000 hours, with an estimated remaining 500 WEOT hours. If the current high load and high dust conditions continue, maintenance is predicted to be required after 100 hours of actual clock time.

[0068] This invention, by introducing engine load and environmental factors as weights, constructs a weighted equivalent operating time model, which can more accurately predict the remaining life of the flame arrester core, thereby providing data support for the maintenance of the flame arrester core, further ensuring the maintenance accuracy of the flame arrester core, and avoiding insufficient or excessive maintenance.

[0069] In one feasible implementation, the predictive maintenance method described in this embodiment of the invention may, but is not limited to, further include: Record the pressure difference change before and after each cleaning event, and correlate it with the average load data and average environmental parameters within the corresponding cleaning cycle of the cleaning event; The weighting coefficients and the correction coefficients are adaptively adjusted using the recursive least squares method to make the weighted equivalent running time model fit the actual pollution accumulation characteristics.

[0070] This invention records the pressure difference change before and after each cleaning event and associates it with the average load data and average environmental parameters within the corresponding cleaning cycle. It employs a recursive least squares method to adaptively correct the weighting coefficients and correction coefficients, creating an adaptive learning mechanism that fits the weighted equivalent operating time model with actual pollution accumulation characteristics. This mechanism can more accurately predict the lifespan of the flame arrester core, thereby improving the maintenance accuracy of the flame arrester core and further avoiding insufficient or excessive maintenance.

[0071] In specific implementation, the adaptive learning mechanism described in this embodiment of the invention is a closed-loop control system, and its logic is as follows: Prediction Phase: The system calculates WEOT and predicts remaining lifespan based on the current weighting coefficient w (load impact) and correction coefficient k (environmental impact). During the initial run, the weighting coefficient w and correction coefficient k can be preset according to the engine model.

[0072] Execution phase: When the differential pressure reaches the threshold, the system performs a cleaning operation.

[0073] Feedback phase: The system records the "effect" of this cleaning, i.e., the change in pressure difference.

[0074] Correction phase: The system compares "how much pollution should accumulate as expected" with "how much pollution was actually cleaned up", and uses this difference to fine-tune w and k.

[0075] Optimization phase: Use the fine-tuned w and k for the next prediction.

[0076] The operation flow of the adaptive learning mechanism is as follows: The first step is to record the "inputs" and "outputs" within a cleaning cycle: Each time a cleaning event occurs, the system records two sets of data: Input (Reason): Average engine load during this cleaning cycle i and average environmental parameter Env i (Dust concentration, humidity, etc.)

[0077] Output (result): The amount of pollutants removed this time, which is the pressure difference change value.

[0078] The second step is to establish the difference between the "expected" and the "actual": The system has an internal expected model: Expected pollution accumulation = Theoretical function (running time, current w, current k) The actual pollution accumulation observed by the system equals the change in pressure difference.

[0079] If the actual pressure difference change is greater than the expected value, it indicates that the system previously underestimated the contamination rate under this operating condition. This means that the current weighting coefficient w or correction coefficient k is set too low and needs to be increased.

[0080] If the actual pressure difference change is less than the expected value, it means that the system previously overestimated the contamination rate, and the current w or k setting is too high and needs to be lowered.

[0081] The third step is to use the recursive least squares (RLS) method for correction.

[0082] In practical implementation, RLS can be understood as an intelligent responsibility assigner. For example: Suppose an engine has been running continuously for two weeks and has undergone two cleanings: Cleaning incident 1: Operating conditions: high load (initial w = 5.0), low dust (initial k = 1.0); ran for 10 hours.

[0083] A lot of ash was actually removed during the cleaning process (due to significant pressure difference changes).

[0084] RLS calculation: The system detected a large error. Analysis suggested that since the environment was not dirty (k was normal), the problem was most likely with the load factor. Therefore, the RLS algorithm adjusted w from 5.0 to 5.3 (increasing the pollution weight for high loads).

[0085] Cleaning incident 2: Operating conditions: The following week, the load remained high (w new=5.3), but a sandstorm occurred, resulting in extremely high dust concentration (k initial=2.0); the system operated for 10 hours.

[0086] The amount of dust actually removed was more than expected.

[0087] RLS operation: The system detected that the error had increased again. Analysis indicated that w had just been calibrated, and the environment was indeed dirtier this time, so the error should be mainly attributed to the environment coefficient k. Therefore, the RLS algorithm adjusted k from 2.0 to 2.2.

[0088] The embodiments of the present invention utilize an adaptive learning mechanism to enable the WEOT model to continuously evolve as equipment ages and the environment changes, thereby achieving increasingly accurate remaining lifetime predictions.

[0089] In one feasible implementation, the multi-parameter status monitoring module 130 in this embodiment of the invention further includes an intake air quality sensor for detecting dust concentration and / or humidity in the intake air, and using the detection data of the intake air quality sensor as the input of the correction coefficient.

[0090] In one feasible implementation, the dynamic prediction of the remaining service life of the flame arrestor core based on the WEOT value in this embodiment of the invention may include, but is not limited to: Determine whether the remaining service life of the flame arrestor core is less than a preset service life alarm threshold. If so, generate and push a predictive maintenance prompt message.

[0091] In specific implementation, this embodiment of the invention pre-sets a lifespan alarm threshold, such as ≤50 hours. When the remaining lifespan of the flame arrester core predicted by the WEOT model is ≤50 hours, the control and decision module 140 automatically generates predictive maintenance prompts and pushes them to maintenance personnel. These predictive maintenance prompts may include, but are not limited to, the device number, flame arrester core model, expected remaining lifespan, and replacement time point; no specific limitations are imposed here.

[0092] Based on the above-described condition-adaptive explosion-proof engine intake flame arrester system, this invention provides a condition-adaptive explosion-proof engine intake flame arrester health management method, applied to any of the above-described condition-adaptive explosion-proof engine intake flame arrester systems. The method includes: Acquire real-time differential pressure data, real-time temperature data, and real-time operating parameters of the engine for the flame arrester core; Determine whether the real-time differential pressure data exceeds a first preset differential pressure threshold and whether the real-time operating parameters are within the allowable cleaning range; if so, dynamically match the cleaning execution parameters according to the real-time operating parameters and generate a cleaning command; according to the cleaning command, control the explosion-proof solenoid valve to drive the pulse nozzle array to perform pulse jet cleaning on the flame arrestor core; Based on the real-time temperature data and the real-time pressure difference data, determine whether there is a safety hazard in the flame arrestor core; if so, trigger a safety warning. Furthermore, based on the weighted equivalent operating time (WEOT) model, the remaining service life of the flame arrester core is predicted, and when the remaining service life of the flame arrester core is less than a preset life alarm threshold, a predictive maintenance prompt message is generated and pushed.

[0093] In some embodiments, the above-described method for health management of explosion-proof engine intake flame arresters based on operating condition adaptation provided in this embodiment of the invention can be executed by any electronic device 20 with data processing capabilities, such as a general-purpose computer, personal computer, laptop computer, switch, or tablet computer, etc. The specific implementation method of the electronic device 20 is not limited here.

[0094] Figure 5 A schematic diagram of the hardware structure of an electronic device provided in an embodiment of the present invention is shown. The electronic device 20 includes a processor 210, a memory 220, and a communication interface 230.

[0095] Processor 210 may include one or more processing cores. Processor 210 connects to various parts within electronic device 200 using various interfaces and lines, and performs various functions and processes data of electronic device 200 by running or executing instructions, programs, code sets, or instruction sets stored in memory 220, and by calling data stored in memory 220. Optionally, processor 210 may be implemented using at least one of the following hardware forms: Central Processing Unit (CPU), Graphics Processing Unit (GPU), Digital Signal Processing (DSP), Field-Programmable Gate Array (FPGA), and Programmable Logic Array (PLA).

[0096] The memory 220 may include random access memory (RAM) or read-only memory (ROM). Optionally, the memory 220 may include a non-transitory computer-readable storage medium. The memory 220 may be used to store instructions, programs, code, code sets, or instruction sets. The memory 220 may include a stored program area. The stored program area may store instructions for implementing an operating system, instructions for implementing at least one function, instructions for implementing the various method embodiments described above, etc.

[0097] Communication interface 230 is used to communicate with other devices, equipment or communication networks, such as data storage devices, image processing devices or Ethernet, wireless access network (RAN), wireless local area network (WLAN), etc.

[0098] In terms of physical implementation, the aforementioned devices (such as processor 210, memory 220, and communication interface 230) can each be devices within the same device (such as a laptop computer). Alternatively, at least two of these devices can be located within the same device, i.e., as different devices within the same device, similar to the deployment of devices or components in a distributed system.

[0099] It is understood that the structure illustrated in this embodiment does not constitute a specific limitation on the electronic device 20. In other embodiments of the present invention, the electronic device 20 may include more or fewer components than illustrated, or combine some components, or split some components, or have different component arrangements. The illustrated components may be implemented in hardware, software, or a combination of software and hardware.

[0100] Based on the aforementioned condition-adaptive health management method for explosion-proof engine intake flame arresters provided in the second aspect, this embodiment of the invention also provides a storage medium storing a computer-executable program. The computer-executable program is used to cause a computer to execute the condition-adaptive health management method for explosion-proof engine intake flame arresters as described in any implementation of the second aspect. Explanations of the relevant content and descriptions of the beneficial effects of any of the computer-readable storage media provided above can be found in the corresponding embodiments described above, and will not be repeated here.

[0101] Those skilled in the art will understand that the program for implementing all or part of the steps of the above embodiments, which can be executed by a program instructing related hardware, can be stored in a computer-readable storage medium. The storage medium mentioned above can be a read-only memory, a random access memory, etc. The processing unit or processor mentioned above can be a central processing unit, a general-purpose processor, an application-specific integrated circuit (ASIC), a microprocessor (DSP), a field-programmable gate array (FPGA), or other programmable logic devices, transistor logic devices, hardware components, or any combination thereof.

[0102] This invention also provides a computer program product containing instructions that, when executed on a computer, cause the computer to perform any of the methods described in the above embodiments. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, all or part of the flow or function according to the embodiments of this invention is generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, computer instructions can be transmitted from one website, computer, server, or data center to another via wired (e.g., coaxial cable, fiber optic, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium accessible to a computer or a data storage device such as a server or data center that integrates one or more available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., SSD), etc.

[0103] It should be noted that the devices for storing computer instructions or computer programs provided in the embodiments of the present invention, such as, but not limited to, the aforementioned memory, computer-readable storage medium, and communication chip, are all non-transitory. Those skilled in the art should recognize that the functions described in the embodiments of the present invention in one or more of the above examples can be implemented using hardware, software, firmware, or any combination thereof. When implemented using software, these functions can be stored in a computer-readable storage medium or transmitted as one or more instructions or code on a computer-readable storage medium. Computer-readable storage media include computer storage media and communication media, wherein communication media include any medium that facilitates the transmission of computer programs from one place to another. Storage media can be any available medium accessible to general-purpose or special-purpose computers.

[0104] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A condition-adaptive explosion-proof engine intake flame arrester system, characterized in that, include: The mechanical body module includes an explosion-proof housing and a flame arrestor core disposed therein; The cleaning execution module includes an air source interface, an explosion-proof solenoid valve, and a pulse nozzle array connected in sequence. The air source interface is connected to the boost air source of the engine, and the pulse nozzle array is located upstream of the flame arrestor. The multi-parameter status monitoring module includes at least a differential pressure sensor that monitors the pressure difference before and after the flame arrester core; The control and decision-making module is electrically connected to the cleaning execution module and the multi-parameter status monitoring module, respectively, and is communicatively connected to the engine ECU. The control and decision module is configured to execute a condition-adaptive cleaning control strategy, which includes: The real-time differential pressure data of the differential pressure sensor and the real-time operating parameters of the engine ECU are acquired, wherein the real-time operating parameters include at least engine speed and load. Determine whether the real-time differential pressure data exceeds a first preset differential pressure threshold, and whether the real-time operating parameters are within a preset allowable cleaning operating range; If so, based on the real-time operating parameters, the cleaning execution parameters are dynamically matched to generate cleaning instructions; According to the cleaning command, the explosion-proof solenoid valve is controlled to drive the pulse nozzle array to perform pulse jet cleaning on the flame arrestor core.

2. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 1, characterized in that, The response time of the explosion-proof solenoid valve is less than 10ms.

3. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 1, characterized in that, The pulse nozzle array is a ring-shaped Venturi pulse nozzle array.

4. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 1, characterized in that, The step of dynamically matching cleaning execution parameters and generating cleaning instructions based on the real-time operating parameters includes: Based on the real-time operating parameters, cleaning execution parameters that match the real-time operating parameters are found from a preset three-dimensional pulse spectrum. The cleaning execution parameters include pulse duration, pulse interval, and number of repetitions.

5. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 1, characterized in that, The multi-parameter status monitoring module further includes a temperature sensor for monitoring the temperature status of the flame arrester core; the control and decision module is also configured to execute a multi-dimensional safety early warning strategy, which includes: Acquire real-time temperature data from the temperature sensor; Based on the real-time temperature data and the real-time differential pressure data, it is determined whether there is a safety hazard in the flame arrestor core. If so, a safety warning is triggered.

6. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 5, characterized in that, The step of determining whether the flame arrestor core has a safety hazard based on the real-time temperature data and the real-time pressure difference data includes: Construct a pressure difference-temperature time-series correlation curve between the real-time temperature data and the real-time pressure difference data; Analyzing the pressure difference-temperature time-series correlation curve, when the real-time pressure difference data is within a preset normal pressure difference range and the real-time temperature data shows local abnormal temperature rise exceeding a preset temperature rise rate threshold, it indicates that the flame arrestor core has a potential risk of backfire; when the real-time pressure difference data is within a preset normal pressure difference range and the real-time temperature data shows uneven temperature distribution exceeding a preset uneven temperature distribution threshold, it indicates that the flame arrestor core has a risk of local hot spots; when the real-time pressure difference abnormally increases and exceeds a second preset pressure difference threshold and the real-time temperature data is within a preset normal temperature range, it indicates that the flame arrestor core has a risk of physical blockage.

7. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 1, characterized in that, The control and decision module is also configured to execute a predictive maintenance method based on weighted equivalent runtime, the predictive maintenance method comprising: The weighted equivalent runtime model is constructed as shown in the following formula: WEOT=∑[t i ×w(load i )×k(Env i )]; Among them, t i For the runtime segment, w(load) i ) represents the weighting coefficient of the average engine load during time period i, and k(Env) represents the weighting coefficient of the average engine load during time period i. i () represents a correction factor based on environmental parameters; The load data of the engine ECU is recorded in real time, and the WEOT value is calculated cumulatively. The remaining service life of the flame arrestor core is dynamically predicted based on the WEOT value.

8. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 7, characterized in that, The predictive maintenance method further includes: Record the pressure difference change before and after each cleaning event, and correlate it with the average load data and average environmental parameters within the corresponding cleaning cycle of the cleaning event; The weighting coefficients and the correction coefficients are adaptively adjusted using the recursive least squares method to make the weighted equivalent running time model fit the actual pollution accumulation characteristics.

9. The explosion-proof engine intake flame arrester system based on operating condition adaptation according to claim 8, characterized in that, The multi-parameter status monitoring module also includes an intake air quality sensor for detecting dust concentration and / or humidity in the intake air, and uses the detection data of the intake air quality sensor as the input of the correction coefficient.

10. A flame arrester system for explosion-proof engines based on adaptive operating conditions according to claim 8, characterized in that, The dynamic prediction of the remaining service life of the flame arrestor core based on the WEOT value includes: Determine whether the remaining service life of the flame arrestor core is less than a preset service life alarm threshold. If so, generate and push a predictive maintenance prompt message.

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