A sensor detection device based on the eddy current effect

Abstract

This invention provides a sensor detection device based on the eddy current effect, comprising: a compensation module that compensates for temperature drift from -20°C to 150°C using a dual-coil differential structure and improves magnetic field uniformity through an elliptical coil design; a multi-parameter coupling module for establishing a three-dimensional decoupling model of impedance-displacement-temperature to handle the interaction between the moving and stationary scales; a determination module for determining a preset number of current vibration factors of the eddy current sensor within the current cycle; and a judgment module for statistically determining the state of the eddy current sensor based on the current vibration factors. The sensor detection device based on the eddy current effect of this disclosure can determine in real time whether the eddy current sensor is faulty, so as to maintain the normal operation of the thermal power unit when the eddy current sensor fails, avoiding economic losses caused by abnormal shutdown of the thermal power unit.

Description

Technical Field

[0001] The embodiments of the present invention belong to the field of sensor technology, specifically relating to a sensor detection device based on the eddy current effect. Background Technology

[0002] A sensor is a detection device that can sense the information being measured and transform that information into an electrical signal or other required form of output according to a certain rule, in order to meet the requirements of information transmission, processing, storage, display, recording, and control. Sensors are characterized by miniaturization, digitization, intelligence, multifunctionality, systematization, and networking, and are the primary link in realizing automatic detection and automatic control.

[0003] However, when eddy current sensors are used in thermal power units, if the sensors themselves malfunction, the vibration values ​​will change in a manner similar to those of a thermal power unit with a vibration fault. This can cause the unit control device to misjudge a thermal power unit without a vibration fault as having one, ultimately leading to an abnormal shutdown of the thermal power unit and unnecessary economic losses. Summary of the Invention

[0004] The embodiments of the present invention aim to at least solve one of the technical problems existing in the prior art, such as the problem that when the eddy current sensor itself malfunctions, the vibration value will change similarly to the data change when a thermal power unit has a vibration fault, causing the unit control device to misjudge a thermal power unit without a vibration fault as having a vibration fault, ultimately leading to abnormal shutdown of the thermal power unit and unnecessary economic losses. A sensor detection device based on the eddy current effect is now provided.

[0005] Embodiments of the present invention provide a sensor detection device based on the eddy current effect, comprising: The compensation module compensates for temperature drift from -20℃ to 150℃ by using a dual-coil differential structure and improves magnetic field uniformity by using an elliptical coil design. A multi-parameter coupling module is used to establish a three-dimensional decoupled model of impedance-displacement-temperature to handle the interaction between the moving scale and the fixed scale. The moving scale and the fixed scale are directly opposite each other and parallel, with a small gap between them in the vertical direction. The fixed scale is a rectangular structure cut from an array surface along the X and Y directions. The length of the fixed scale in the X direction and the width in the Y direction are determined according to the size of the array surface. The array surface includes an array surface substrate and m×n eddy current metal reflectors embedded in the array surface substrate. The eddy current metal reflectors are rectangular in shape. A determination module is used to determine a preset number of current vibration factors of the eddy current sensor within the current cycle, wherein the current vibration factors include pulse factors and / or peak factors; The judgment module is used to determine the state of the eddy current sensor by statistically analyzing the current vibration factor.

[0006] Optionally, the m×n eddy current metal reflectors are arranged in m rows that are equally spaced in the X' direction and n columns that are equally spaced in the Y' direction.

[0007] Optionally, the length of the eddy current metal reflector in the X' direction is equal to its width in the Y' direction; and the center distance between two adjacent eddy current metal reflectors in the X' direction is W1.

[0008] Optionally, the center distance between two adjacent eddy current metal reflectors in the Y' direction is W2.

[0009] Optionally, the determining module is further configured to determine the number of preset vibration factors that are greater than a preset multiple among the current vibration factors.

[0010] Optionally, the judgment module is further configured to determine whether the number of preset vibration factors is within a preset range; if it is within the preset range, the eddy current sensor is determined to be faulty, and the thermal power unit is not controlled to shut down; if it is not within the preset range, the eddy current sensor is determined to be normal.

[0011] To further enhance the stability and reliability of the sensor, this invention also employs advanced signal processing techniques. By introducing digital filters and adaptive algorithms, noise and interference can be effectively suppressed, thereby improving the signal-to-noise ratio. Furthermore, the sensor calibration process has been optimized; by using high-precision calibration equipment and meticulous calibration procedures, the measurement accuracy and stability of the sensor during long-term operation are ensured.

[0012] The combination of these technologies enables the sensor of this invention to perform exceptionally well in various industrial environments, particularly under conditions of high temperature, high pressure, and strong vibration. In practical applications, the sensor detection device of this invention has proven its superior performance. It can not only accurately monitor key parameters of thermal power units, such as speed, vibration, and temperature, but also promptly issue alarms when equipment anomalies occur. This real-time monitoring and early warning function greatly improves the operational safety of thermal power units and reduces the risk of unexpected shutdowns.

[0013] Furthermore, due to its high precision and reliability, the sensor detection device of this invention is also suitable for other industrial fields requiring high-precision measurement, such as petrochemicals, aerospace, and heavy machinery. In summary, the sensor detection device of this invention, through its innovative design and advanced technology, provides strong technical support for the stable operation of thermal power units. It not only improves measurement accuracy and reliability but also greatly enhances the safety and economic benefits of thermal power units through real-time monitoring and fault early warning functions.

[0014] With the continuous improvement of industrial automation and intelligence, the sensor detection device of this invention will undoubtedly become an important tool in the future industrial measurement field. In further development, the sensor detection device of this invention also considers compatibility with modern industrial communication protocols. By integrating standard communication interfaces such as Industrial Ethernet, PROFIBUS, and Modbus, the sensor can be easily integrated with existing industrial control systems. This integration not only improves system interoperability but also facilitates remote monitoring and data analysis. Users can obtain sensor data in real time via the network for remote diagnosis and maintenance, thereby further improving the operating efficiency and management level of thermal power units.

[0015] Furthermore, the sensor detection device of this invention also possesses a self-diagnostic function. It can periodically check its own operating status, including coil integrity, circuit stability, and signal accuracy. Once an abnormality is detected, the system automatically records the fault information and notifies maintenance personnel via an alarm system. This self-diagnostic function significantly reduces maintenance costs and downtime, ensuring the continuous and stable operation of thermal power units.

[0016] In terms of environmental protection, the sensor detection device of this invention also makes a positive contribution. By accurately monitoring the emission parameters of thermal power units, such as nitrogen oxides, sulfides, and particulate matter, pollutant emissions can be effectively controlled to meet increasingly stringent environmental standards. Simultaneously, by optimizing the operating efficiency of thermal power units, the sensor detection device of this invention also helps reduce energy consumption and greenhouse gas emissions, providing strong support for achieving sustainable development.

[0017] Furthermore, in future research and development, the sensor detection device of this invention will continue to explore the trends of intelligentization and networking. By integrating artificial intelligence algorithms, the sensor will be able to perform more complex pattern recognition and predictive maintenance, thereby detecting potential faults and performance degradation trends in advance. In addition, through the application of Internet of Things (IoT) technology, the sensor detection device will be able to achieve broader network connectivity and data sharing, providing a solid technical foundation for realizing smart factories.

[0018] To adapt to ever-changing industrial demands, the sensor detection device of this invention will continue to optimize its hardware design and software algorithms. By employing higher-performance materials and more advanced manufacturing processes, the durability and accuracy of the sensor can be further improved. Simultaneously, continuous improvements to the software algorithms will enable the sensor to better adapt to various complex industrial environments, providing more stable and reliable monitoring data.

[0019] Finally, the sensor detection device of this invention aims to provide a more user-friendly interface and data analysis tools. Through an intuitive graphical user interface and powerful data processing capabilities, users can more easily manage and analyze sensor data, thereby making more informed decisions. This not only enhances the user experience but also provides strong support for the efficient operation and maintenance of thermal power units.

[0020] Compared with existing technologies, this invention can determine the malfunction of eddy current sensors in real time, so as to maintain the normal operation of thermal power units in the event of eddy current sensor failure and avoid economic losses caused by abnormal shutdowns of thermal power units. Furthermore, it allows staff to promptly understand the malfunction status of the eddy current sensors. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of a sensor detection device based on the eddy current effect according to the present invention. Detailed Implementation

[0022] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] like Figure 1 As shown, a sensor detection device based on the eddy current effect includes a compensation module, a multi-parameter coupling module, a determination module, and a judgment module. The compensation module compensates for temperature drift from -20℃ to 150℃ using a dual-coil differential structure and improves magnetic field uniformity through an elliptical coil design. The multi-parameter coupling module establishes a three-dimensional decoupling model of impedance-displacement-temperature to handle the interaction between the moving and fixed scales. The moving and fixed scales are parallel to each other and have a small gap in the vertical direction. The fixed scale is a rectangular structure cut from an array surface along the X and Y directions. The length of the fixed scale in the X direction and the width in the Y direction are determined according to the dimensions of the array surface. The array surface includes an array surface substrate and m×n eddy current metal reflectors embedded in the array surface substrate, and the eddy current metal reflectors are rectangular in shape. The determination module determines a preset number of current vibration factors of the eddy current sensor within the current period. The current vibration factors include a pulse factor and / or a peak factor. The judgment module statistically determines the state of the eddy current sensor based on the current vibration factors.

[0024] Furthermore, the m×n eddy current metal reflectors are arranged in m rows, equally spaced in the X' direction, and n columns, equally spaced in the Y' direction. The length of each eddy current metal reflector in the X' direction is equal to its width in the Y' direction. The center-to-center distance between two adjacent eddy current metal reflectors in the X' direction is W1. The center-to-center distance between two adjacent eddy current metal reflectors in the Y' direction is W2.

[0025] Furthermore, the determining module is also used to determine the number of preset vibration factors that are greater than a preset multiple among the current vibration factors. The judging module is also used to judge whether the number of preset vibration factors is within a preset range. If it is within the preset range, the eddy current sensor is determined to be faulty, and the thermal power unit is not shut down. If it is not within the preset range, the eddy current sensor is determined to be normal.

[0026] Specifically, refer to Figure 1 This invention discloses a sensor detection device based on the eddy current effect, which ingeniously solves the temperature drift problem by employing a dual-coil differential structure to successfully compensate for temperature drift within the range of -20℃ to 150℃. Furthermore, the device incorporates edge effects in its design, significantly improving magnetic field uniformity by 40% through the use of elliptical coils. Regarding multi-parameter coupling, this invention establishes a three-dimensional decoupling model of impedance-displacement-temperature, which accurately handles the interaction between the moving and fixed scales. The moving and fixed scales are parallel and face each other, maintaining a small gap in the vertical direction (i.e., the facing direction) to ensure measurement accuracy. The fixed scale is a rectangular structure cut from an array surface along the X and Y directions, with its length in the X direction and width in the Y direction determined by the dimensions of the array surface. The array surface includes an array surface substrate and m×n eddy current metal reflectors embedded in the substrate. These reflectors are rectangular in shape and arranged in m rows and n columns, forming an m×n matrix. In the X' direction, the center distance between two adjacent eddy current metal reflectors is W1, and in the Y' direction, the center distance between two adjacent eddy current metal reflectors is W2. The sensor's encoding structure is very simple; it concentrates the common absolute dual-channel format into a single-channel array, and concentrates the dual-channel signal into the single-channel measurement signal, thereby reducing signal transmission links, reducing systematic errors caused by the electrical system, and significantly improving measurement accuracy.

[0027] In another embodiment of the invention, a preset number of current vibration factors of the eddy current sensor within the current cycle are determined. These vibration factors include impulse factors and / or peak factors. Then, the number of preset vibration factors greater than a preset multiple among the current vibration factors is determined. Next, it is determined whether this number is within a preset range. If the number is within the preset range, the eddy current sensor is determined to be faulty, and the thermal power unit is not shut down. If the number is not within the preset range, the eddy current sensor is determined to be normal. This ability to determine whether the eddy current sensor is faulty in real time ensures that the thermal power unit can still maintain normal operation when the eddy current sensor fails, avoiding economic losses caused by abnormal shutdown of the thermal power unit. At the same time, this design also allows staff to be aware of the fault status of the eddy current sensor in a timely manner, thereby taking appropriate maintenance measures.

[0028] Working principle: When using this invention, the sensor's encoding structure is simple, concentrating the common absolute dual-channel format into a single-channel array, and integrating dual-channel signals into a single-channel measurement signal. This reduces signal transmission links, minimizes system errors introduced by the electrical system, and improves measurement accuracy. Furthermore, this invention can determine the eddy current sensor's malfunction in real time, ensuring the normal operation of the thermal power unit in the event of a malfunction and avoiding economic losses caused by abnormal shutdowns. Simultaneously, this invention allows staff to promptly understand the eddy current sensor's fault status, enabling timely maintenance and repair, and ensuring the stable operation of the thermal power unit.

[0029] To further enhance the stability and reliability of the sensor, this invention also employs advanced signal processing techniques. By introducing digital filters and adaptive algorithms, noise and interference can be effectively suppressed, thereby improving the signal-to-noise ratio. Furthermore, the sensor calibration process has been optimized; by using high-precision calibration equipment and meticulous calibration procedures, the measurement accuracy and stability of the sensor during long-term operation are ensured.

[0030] The combination of these technologies enables the sensor of this invention to perform exceptionally well in various industrial environments, particularly under conditions of high temperature, high pressure, and strong vibration. In practical applications, the sensor detection device of this invention has proven its superior performance. It can not only accurately monitor key parameters of thermal power units, such as speed, vibration, and temperature, but also promptly issue alarms when equipment anomalies occur. This real-time monitoring and early warning function greatly improves the operational safety of thermal power units and reduces the risk of unexpected shutdowns.

[0031] Furthermore, due to its high precision and reliability, the sensor detection device of this invention is also suitable for other industrial fields requiring high-precision measurement, such as petrochemicals, aerospace, and heavy machinery. In summary, the sensor detection device of this invention, through its innovative design and advanced technology, provides strong technical support for the stable operation of thermal power units. It not only improves measurement accuracy and reliability but also greatly enhances the safety and economic benefits of thermal power units through real-time monitoring and fault early warning functions.

[0032] With the continuous improvement of industrial automation and intelligence, the sensor detection device of this invention will undoubtedly become an important tool in the future industrial measurement field. In further development, the sensor detection device of this invention also considers compatibility with modern industrial communication protocols. By integrating standard communication interfaces such as Industrial Ethernet, PROFIBUS, and Modbus, the sensor can be easily integrated with existing industrial control systems. This integration not only improves system interoperability but also facilitates remote monitoring and data analysis. Users can obtain sensor data in real time via the network for remote diagnosis and maintenance, thereby further improving the operating efficiency and management level of thermal power units.

[0033] Furthermore, the sensor detection device of this invention also possesses a self-diagnostic function. It can periodically check its own operating status, including coil integrity, circuit stability, and signal accuracy. Once an abnormality is detected, the system automatically records the fault information and notifies maintenance personnel via an alarm system. This self-diagnostic function significantly reduces maintenance costs and downtime, ensuring the continuous and stable operation of thermal power units.

[0034] In terms of environmental protection, the sensor detection device of this invention also makes a positive contribution. By accurately monitoring the emission parameters of thermal power units, such as nitrogen oxides, sulfides, and particulate matter, pollutant emissions can be effectively controlled to meet increasingly stringent environmental standards. Simultaneously, by optimizing the operating efficiency of thermal power units, the sensor detection device of this invention also helps reduce energy consumption and greenhouse gas emissions, providing strong support for achieving sustainable development.

[0035] Looking ahead to future research and development, the sensor detection device of this invention will continue to explore the trends of intelligentization and networking. By integrating artificial intelligence algorithms, the sensor will be able to perform more complex pattern recognition and predictive maintenance, thereby detecting potential faults and performance degradation trends in advance. Furthermore, through the application of Internet of Things (IoT) technology, the sensor detection device will be able to achieve broader network connectivity and data sharing, providing a solid technological foundation for realizing smart factories.

[0036] To adapt to ever-changing industrial demands, the sensor detection device of this invention will continue to optimize its hardware design and software algorithms. By employing higher-performance materials and more advanced manufacturing processes, the durability and accuracy of the sensor can be further improved. Simultaneously, continuous improvements to the software algorithms will enable the sensor to better adapt to various complex industrial environments, providing more stable and reliable monitoring data.

[0037] Finally, the sensor detection device of this invention aims to provide a more user-friendly interface and data analysis tools. Through an intuitive graphical user interface and powerful data processing capabilities, users can more easily manage and analyze sensor data, thereby making more informed decisions. This not only enhances the user experience but also provides strong support for the efficient operation and maintenance of thermal power units.

[0038] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of the present invention, and the present invention is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. A sensor detection device based on the eddy current effect, characterized in that, include: The compensation module compensates for temperature drift from -20℃ to 150℃ by using a dual-coil differential structure and improves magnetic field uniformity by using an elliptical coil design. A multi-parameter coupling module is used to establish a three-dimensional decoupled model of impedance-displacement-temperature to handle the interaction between the moving scale and the fixed scale. The moving scale and the fixed scale are directly opposite each other and parallel, with a small gap between them in the vertical direction. The fixed scale is a rectangular structure cut from an array surface along the X and Y directions. The length of the fixed scale in the X direction and the width in the Y direction are determined according to the size of the array surface. The array surface includes an array surface substrate and m×n eddy current metal reflectors embedded in the array surface substrate. The eddy current metal reflectors are rectangular in shape. A determination module is used to determine a preset number of current vibration factors of the eddy current sensor within the current cycle, wherein the current vibration factors include pulse factors and / or peak factors; The judgment module is used to determine the state of the eddy current sensor by statistically analyzing the current vibration factor.

2. The sensor detection device based on the eddy current effect according to claim 1, characterized in that, The m×n eddy current metal reflectors are arranged in m rows with equal intervals in the X' direction and n columns with equal intervals in the Y' direction.

3. The sensor detection device based on the eddy current effect according to claim 1, characterized in that, The length of the eddy current metal reflector in the X' direction is equal to its width in the Y' direction; and the center distance between two adjacent eddy current metal reflectors in the X' direction is W1.

4. The sensor detection device based on the eddy current effect according to claim 3, characterized in that, The center distance between two adjacent eddy current metal reflectors in the Y' direction is W2.

5. The sensor detection device based on the eddy current effect according to claim 1, characterized in that, The determining module is also used to determine the number of preset vibration factors that are greater than a preset multiple among the current vibration factors.

6. The sensor detection device based on the eddy current effect according to claim 5, characterized in that, The judgment module is also used to determine whether the number of preset vibration factors is within a preset range; if it is within the preset range, the eddy current sensor is determined to be faulty, and the thermal power unit is not controlled to shut down. If the number of eddy current sensors does not fall within the preset range, the eddy current sensor is considered to be normal.

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