A robot working system for calibrating velocity field coefficients, its installation structure, and calibration method.

Abstract

This invention discloses a velocity field coefficient calibration robot system, its installation structure, and calibration method. The velocity field coefficient calibration robot system includes a velocity field coefficient calibration robot, a track, and a return capsule. The velocity field coefficient calibration robot includes a component compartment and a flow velocity reference probe. The flow velocity reference probe is mounted on the component compartment, and the distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is not less than 20 cm. The track is helical. The head end of the track extends into and connects to the return capsule. The component compartment of the velocity field coefficient calibration robot is connected to the track. The velocity field coefficient calibration robot can run along the length of the track and can also enter the return capsule. This invention realizes automated and high-precision operation of large-diameter flue gas flow calibration, ensuring the accuracy, reliability, and traceability of measurement data, and reducing operating costs and safety risks.

Description

Technical Field

[0001] This invention relates to a robot working system for calibrating velocity field coefficients, its installation structure, and calibration method, belonging to the field of large-diameter flow measurement and calibration technology. Background Technology

[0002] Under the national "dual-carbon" strategy, building a rigorous, scientific, and traceable carbon emission monitoring system has become a core foundation for achieving a green and low-carbon transformation. Recently issued national regulations, such as the "Regulations on Ecological and Environmental Monitoring," the "Technical Guidelines for Online Monitoring of Boiler Carbon Emissions," and the "Technical Specifications for Setting Monitoring Points at Pollutant Discharge Outlets of Pollutant Discharge Units," not only comprehensively incorporate carbon emission monitoring into the legal regulatory framework but also set forth clear requirements for the selection of key monitoring equipment. For boiler equipment in the thermal power industry, it is clarified that under "unstable and non-uniform flow field" operating conditions, the flue gas velocity measurement method should use either multi-channel through-type line measurement or grid-based point measurement (the measuring points must meet the requirements of GB / T 16157). The former refers to multi-channel ultrasonic flow meters, and the latter refers to standard grid-based flow meters.

[0003] In China, matrix flow meters or ultrasonic flow meters are commonly used for carbon emission monitoring and flow measurement of thermal power units. These devices are typically installed on the chimney or in the flue from the desulfurization outlet to the chimney inlet. The measured values ​​need to be corrected by the velocity field coefficient to achieve accurate measurement, which means that the standard grid method specified in the national standard is used for on-site calibration.

[0004] Currently, on-site calibration of flue gas flow in thermal power units faces several practical challenges: First, the flue is installed at a high position with a large flow cross-section (typically 6m×8m, 6m×10m, etc.), and the larger the unit capacity, the larger the flue cross-section. There is no dedicated measurement platform around the flue, and the flue wall lacks space for pre-drilled test or measurement holes, making calibration impossible and lacking the necessary conditions for manual calibration. Second, manual calibration requires a measuring rod with a standard Pitot tube inserted into the flue. Due to the large flue cross-section, the measuring rod is too long, making it difficult to accurately locate the grid center. The flow of flue gas within the flue causes the measuring rod to sway, significantly reducing measurement accuracy. Third, manual calibration is extremely physically demanding for operators, and changes in unit load can affect calibration results. Differences in operation by different calibration personnel and equipment can easily lead to significant deviations, making it impossible to guarantee data accuracy. Fourth, measurement data relies on manual recording, resulting in management uncertainties, a lack of effective traceability, and an inability to meet the requirements for the authenticity of measurement data. Fifth, on-site calibration needs to be carried out frequently, leading to high labor and equipment costs, and outdoor high-altitude operations pose significant personal safety hazards.

[0005] The existing manual calibration methods can no longer meet the development needs of accurate carbon emission measurement in thermal power units. The industry urgently needs an automated, high-precision, and high-safety flow calibration device to achieve standardized grid calibration of large-diameter flues, ensure the accuracy, reliability, and traceability of carbon emission monitoring data, and at the same time reduce the labor costs and safety risks of calibration operations. Summary of the Invention

[0006] This invention provides a velocity field coefficient calibration robot system, its installation structure, and calibration method. It is applicable to standardized grid calibration of large-diameter flues, achieving automated, high-precision, and highly safe calibration. The calibration is accurate, reliable, traceable, and low-cost.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0008] A velocity field coefficient calibration robot system includes a velocity field coefficient calibration robot, a track, and a return capsule;

[0009] The velocity field coefficient calibration robot includes a component compartment and a flow velocity reference probe. The flow velocity reference probe is installed on the component compartment, and the distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is not less than 20cm.

[0010] The track is spiral-shaped; the front end of the track extends into the return capsule.

[0011] The component compartment of the velocity field coefficient calibration robot is connected to the track. The velocity field coefficient calibration robot can run along the length of the track or enter the return capsule.

[0012] In use, the return capsule is located on the outer wall of the flue, and the head end of the track extends into the return capsule and is connected to it; or, the head end of the track extends into the return capsule but is not connected to the inner wall of the return capsule.

[0013] The distance between the measuring end of the aforementioned flow velocity reference probe and any side wall of the component compartment is not less than 20cm, which can reduce airflow interference and improve the accuracy of calibration.

[0014] For easy assembly and disassembly, the aforementioned flow rate reference probe is detachably mounted on the component compartment, meaning that the flow rate reference probe can be adjusted and replaced with different specifications to adapt to different measurement scenarios.

[0015] The above system is suitable for standardized grid calibration of large-diameter flues, with a simple structure and high accuracy.

[0016] The aforementioned component compartment is also equipped with a differential pressure sensor, a data processing module, and a two-way laser ranging module. Both the differential pressure sensor and the two-way laser ranging module are connected to the data processing module. The differential pressure sensor is also connected to a flow velocity reference probe to collect the differential pressure signal transmitted by the flow velocity reference probe and transmit it to the data processing module to obtain the average flow velocity Vs of the flue measurement section. The two-way laser ranging module is used to obtain the lateral and longitudinal distances inside the flue and transmit them to the data processing module to obtain the cross-sectional area Fs of the flue measurement section. The data processing module is used to collect, analyze, store, and transmit data in real time.

[0017] Using the above scheme, the cross-sectional area Fs of the reference method measurement section can be accurately obtained. According to the provisions of the "G.4 Field Detection Method of Flue Gas Velocity Monitoring Unit" section in standard GB / T 45869, the velocity field coefficient can be calculated.

[0018] Due to the large dimensions of large-diameter flues, significant deformation often occurs during processing, installation, and use, resulting in non-regular square shapes. Therefore, simple length and width measurements cannot accurately obtain the cross-sectional area. This application, through the setting of a bidirectional laser ranging module, can obtain the average length and average width of the measured cross-section, thereby accurately obtaining the cross-sectional area Fs of the reference method's measuring end face, improving the accuracy of calibration.

[0019] The differential pressure sensors mentioned above can be selected from Emerson's Rosemount 3051 series differential pressure transmitter, PRETRANS EDX 7050 series differential pressure transmitter, Setra's Model 269 series differential pressure sensor, etc., which can convert pressure into digital quantity and transmit it remotely.

[0020] The data processing modules mentioned above can be PLCs or microcontrollers. Examples of PLCs include the XD5E-24R main unit and XD E4AD2DA analog input / output module from Xinje, or the CPU 1215C main unit and SM 1231 analog input module from Siemens. Examples of microcontrollers include the NAFE33352-EVB general-purpose AIO-AFE evaluation board from NXP, and the STM32F407-STD industrial control board from Hard Rock Technology.

[0021] The aforementioned bidirectional laser ranging module emits lasers simultaneously in both left and right directions, and the total measured distance is the sum of the distances measured by each laser beam. This device can be a standalone bidirectional laser rangefinder, such as the MAGPIE Saber X laser rangefinder, or it can be composed of two independent unidirectional laser rangefinders, such as the Schott SDD-LAS20 laser rangefinder sensor or the KKIT TLS-20C high-precision laser rangefinder displacement sensor. All of these models support RS485 or RS232 bus protocols, allowing measurement results to be output to a data processing module.

[0022] To extend its service life, the component compartment is also equipped with a temperature control module, which is connected to the data processing module. The temperature control module is used to prevent the components inside the return compartment from overheating, maintain the normal operation of the robot's internal components, and transmit temperature data to the data processing module.

[0023] The temperature control module can be either an electrically controlled temperature control module or a simple dry ice pack temperature control module (including a dry ice pack for cooling and a temperature sensor; the temperature sensor transmits the real-time temperature of the component compartment to the data processing module to monitor the temperature and the operating status of the dry ice pack). The preferred method is to use a dry ice pack temperature control module, which is simple, convenient, space-saving, and low-cost.

[0024] The aforementioned electrically controlled temperature control module can be selected from the TCB-NE series temperature control board produced by Xiafan Optoelectronics Technology, the STXF-TCB series temperature control board produced by Xinte Optoelectronics, and the STJ-JT series TEC temperature controller produced by Xinte Optoelectronics.

[0025] Each of the above modules is independently packaged and treated with waterproof and corrosion-resistant measures to adapt to the harsh working environment inside the flue.

[0026] The aforementioned differential pressure sensor acquires the flue gas differential pressure signal transmitted by the flow velocity reference probe, providing basic data for flow calculation. Its signal acquisition accuracy is adaptable to detecting minute flow changes in large-diameter flues. The data processing module employs an embedded processing chip, capable of real-time filtering, comparative analysis, and defective data identification and removal from the acquired raw data. It eliminates abnormal data caused by flue gas disturbances and simultaneously performs real-time data storage, format conversion, and transmission. Data transmission methods can be selected based on the flue gas environment, such as Bluetooth, WiFi, or UWB, enabling wireless, real-time interaction between measurement data and external terminals, providing digital support for data traceability.

[0027] To further enhance usability, the system also includes a vision sensor mounted on the outer wall of the component compartment and connected to the data processing module. The vision sensor detects real-time environmental images within the flue and transmits them to the data processing module, which processes the images and sends them to the operator, facilitating real-time monitoring of the flue's internal environment. Furthermore, when the vision sensor detects an insurmountable obstacle ahead, the data processing module stops the component compartment's movement relative to the track and issues an alarm signal, reducing or preventing robot malfunctions and damage.

[0028] The aforementioned visual sensors are preferably installed on the front and sides of the robot's movement direction, and adopt existing high-temperature resistant and dust-proof lens designs.

[0029] To ensure the stability of the system, as one preferred implementation, the component cabin of the velocity field coefficient calibration robot is connected to the track via a suspension drive device;

[0030] The longitudinal section of the above track is an "I" structure. One end of the track is provided with a first protrusion for connecting with the mounting bracket inside the flue, and the other end of the track is provided with a second protrusion.

[0031] The suspension drive unit includes a drive motor, a brake mechanism, a mounting block, a lower roller, side rollers, and an upper roller; one side of the mounting block is connected to the component compartment, and the other side is provided with a U-shaped travel groove. The lower roller is installed at the bottom of the travel groove, the upper roller is installed at the two shoulders of the travel groove, and the side rollers are installed on both sides of the travel groove located below the two shoulders.

[0032] The second protrusion on the track matches the travel groove of the mounting block and forms a rolling engagement with the lower roller, side roller and upper roller. This ensures the stability of operation and allows the robot to be reliably suspended on the track in any posture, effectively resisting the impact of flue gas in the flue.

[0033] The drive motor is connected to the lower roller and is used to drive the lower roller to rotate; the brake mechanism is connected to the lower roller or the drive motor and is used to brake the lower roller to control its rotation.

[0034] The aforementioned suspension drive device can overcome the effects of the robot's own weight, track friction, and the disturbance force of the medium flow in the flue, enabling the robot to run stably on the preset track in the flue and to stop on the track in any posture.

[0035] The power output end of the aforementioned drive motor is connected to the lower roller drive to drive the lower roller to rotate and enable the robot to walk; the brake mechanism is set corresponding to the lower roller and forms a braking engagement with the lower roller or the drive motor shaft; when the brake mechanism is activated, it can apply braking force to the lower roller or the drive motor shaft to limit or prevent the roller from rotating, thereby achieving braking and enabling the robot to stop quickly and stably at the center of the grid, meeting the requirements of fixed-point measurement.

[0036] The connection between the drive motor and the lower roller, and the connection between the brake mechanism and the lower roller or the drive motor, can be found in the product manual or existing mature technology. This application does not make any special improvements in this regard, so it will not be described in detail here.

[0037] For ease of use and deployment, the track is in the shape of a rectangular spiral, and the turning points of the track are transitioned by an arc with a radius of not less than 10cm. This avoids problems such as jamming or derailment when the robot turns, ensuring smooth operation.

[0038] To extend the service life of the rails, they are made of corrosion-resistant materials or have an anti-corrosion coating on their outer walls. Corrosion-resistant materials can be polytetrafluoroethylene (PTFE), phenolic or vinyl ester resin fiberglass, etc.; anti-corrosion coatings can be phenolic modified epoxy resin coatings, polyphenylene sulfide (PPS) anti-corrosion coatings, etc.

[0039] The aforementioned flow rate reference probes are any one of the following: S-type Pitot tubes, L-type Pitot tubes, or 3D Pitot tubes. All use quick-connect interfaces to fit the component compartment, making replacement convenient and highly versatile.

[0040] To improve measurement accuracy, a three-dimensional pitot tube is used as the flow velocity reference probe.

[0041] To improve calibration accuracy, preferably, the distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is not less than 50cm.

[0042] For ease of use, the flow velocity reference probe features a retractable and rotatable adjustable structure, enabling precise adjustment of the measurement distance and angle based on the grid center position. The aforementioned retractable and rotatable adjustable structure can be directly derived from existing mature technologies; this application does not offer any significant improvements and therefore will not elaborate further.

[0043] To facilitate rescue in case of failure, rescue hooks are installed around the outer wall of the component compartment. When the velocity field coefficient calibration robot stops due to failure, the operator can load the rescue robot onto the track, connect the traction mechanism of the rescue robot to the rescue hook of the failed robot, and use the rescue robot to tow the failed velocity field coefficient calibration robot into the return compartment for repair. This eliminates the need for personnel to enter the flue to work, reducing the safety risks of fault handling.

[0044] The installation structure of the aforementioned velocity field coefficient calibration robot working system is installed on the flue.

[0045] The flue is equipped with mounting brackets, and the track is mounted on the mounting brackets; the return capsule is located outside the flue; the head end of the track extends out of the flue and into the return capsule;

[0046] The velocity field coefficient calibration robot runs from the head end to the tail end of the track. The measuring end of the flow velocity reference probe passes through all the measuring points arranged in a grid method in the flue. The number of measuring points meets the requirements of GB / T 16157.

[0047] The grid method refers to dividing the cross section into several rectangles of equal area that are close to squares using latitude and longitude lines. Points are taken at the intersection of the diagonals of each small rectangle. This is the grid method point selection. See GB / T 10184-2015 "Principles of Equal Area Division and Determination of Representative Points in Grid Method".

[0048] To facilitate track installation and measurement position control, the mounting bracket is a rectangular grid of equal area, meaning it consists of a grid of rectangular grids (rectangular borders) of equal area. The track is mounted on the mounting bracket in a rectangular spiral shape, passing through each rectangular grid of the bracket. The track is offset from the center of each rectangular grid and is parallel to the line connecting the centers of each rectangular grid. The velocity reference probe is perpendicular to the track's direction. When the velocity field coefficient calibration robot moves from the head end to the tail end of the track or vice versa, the measuring end of the velocity reference probe passes through the center of each rectangular grid.

[0049] To minimize measurement time and maximize calibration efficiency, a rectangular tapering spiral shape is preferred for the track; the track's structure gradually spirals from the inside and outside of the flue towards the center from the beginning to the end. This spiral track design allows the robot to complete continuous measurements of all grids along a single track without frequent track changes or active steering, simplifying the drive mechanism and significantly improving calibration efficiency.

[0050] The aforementioned track and mounting bracket are arranged in a staggered manner, so that they are not on the same cross section, to avoid interference between the robot and the mounting bracket during operation.

[0051] The robot described above can ensure that the flow velocity reference probe can move precisely to the center position of each grid by adjusting the extension and retraction of the flow velocity reference probe and setting a preset track, thus meeting the calibration requirements of the standard grid method.

[0052] For ease of maintenance, the return capsule is located at a maintenance platform on the top edge or side wall edge of the flue. An entrance / exit is located at the intersection of the track and the flue wall, with an automatic hatch on the entrance / exit. The hatch is equipped with elastic sealing gaskets around its perimeter, which can seal the entrance / exit. The automatic hatch is equipped with a sensing module. The automatic hatch opens automatically when the velocity field coefficient calibration robot approaches and closes automatically after the robot passes, thus achieving a seal. This can be implemented by referring to existing sensor door technology.

[0053] The automatic hatch in this application can use existing products, such as the structure disclosed in the patent application number CN201911271001.9, the NAX airtight automatic door produced by NABCO, and the Kaiser CS-HT series integral vertical sealing automatic airtight door produced by Kaiser Door Control, etc.

[0054] The aforementioned return capsule, serving as the base station for the velocity field coefficient calibration robot, is positioned at the top edge or side wall edge of the flue, where a maintenance platform is located, facilitating equipment installation, debugging, and maintenance by operators. An entrance / exit is located at the connection between the return capsule and the flue wall, equipped with an automatic hatch. The hatch uses an elastic sealing gasket to seal against the flue, effectively preventing the leakage of high-temperature flue gas and dust, while also preventing external debris from entering the flue. The automatic hatch is equipped with a sensing module; when the velocity field coefficient calibration robot moves near the hatch, the sensing module detects the robot's signal and controls the hatch to open automatically. After the robot passes through the hatch, it automatically closes, restoring the seal and ensuring the normal operation of the flue.

[0055] A method for calibrating velocity field coefficients, implemented using the aforementioned mounting structure, includes the following steps:

[0056] 1) The velocity field coefficient calibration robot runs from the head end to the tail end of the track, and continuously measures in real time during the operation and / or stops at each measurement point to measure individually;

[0057] 2) The velocity field coefficient calibration robot runs from the tail end of the track to the head end, and continuously measures in real time during the operation and / or stops at each measurement point it passes to measure individually;

[0058] 3) Compare the measurement data obtained in steps 1) and 2). When the deviation of the data obtained by each measurement point in steps 1) and 2) is less than 5%, the average value of the data obtained by each measurement point in steps 1) and 2) is used as the calibration basis value. When the deviation of the data obtained by at least one measurement point in steps 1) and 2) is greater than or equal to 5%, repeat steps 1) and 2) until the deviation of the data obtained by each measurement point in steps 1) and 2) is less than 5%, and use the average value of the data obtained by each measurement point in steps 1) and 2) as the calibration basis value.

[0059] 4) After the measurement is completed, the velocity field coefficient calibration robot returns to the return capsule to wait for further instructions.

[0060] In step 3) above, when the data deviations obtained by each measurement point in steps 1) and 2) are all <5%, the average value of the data obtained by each measurement point in steps 1) and 2) is used as the calibration basis value. That is, the average flow velocity of the measurement end face is calculated using the average value of the data obtained by each measurement point in steps 1) and 2) as the reference method for measuring the average flow velocity of the end face. Then, according to the provisions of the "G.4 Field Detection Method of Flue Gas Velocity Monitoring Unit" section in standard GB / T 45869, the velocity field coefficient is calculated.

[0061] After completing the first round of fixed-point measurements at all grid centers, the aforementioned velocity field coefficient calibration robot will return along the original track, stop again at each grid center measurement point, and measure data, thus achieving two round trips of data measurement. Operators can compare and analyze the two sets of measurement data through an external terminal to confirm whether the working conditions are stable, thereby further improving the accuracy and reliability of the measurement results.

[0062] Combining this application with mature existing technologies, the operating program of the aforementioned velocity field coefficient calibration robot can be pre-set according to the grid layout of the flue, supporting remote start, pause, and termination operations. Its measurement method is highly flexible, and three modes can be selected according to actual calibration needs: First, continuous real-time measurement during operation, with the flow velocity reference probe continuously collecting data as the robot runs along the track, suitable for dynamic monitoring of flue flow; Second, stopping at preset measurement point positions for individual measurement, with the robot stopping after reaching the center of each grid and collecting data again after the measurement data stabilizes, which is the preferred measurement mode and suitable for fixed-point calibration using the standard grid method; Third, a combination of the above two methods, with continuous measurement followed by re-measurement at the grid center position, taking into account both dynamic monitoring and fixed-point calibration needs.

[0063] During the measurements in steps 1) and 2) above, the differential pressure sensor collects the differential pressure signal transmitted by the flow velocity reference probe and transmits it to the data processing module to obtain the average flow velocity Vs of the flue measurement section; at the same time, the bidirectional laser ranging module measures the lateral and longitudinal distances of each point in the flue and transmits them to the data processing module to obtain the cross-sectional area Fs of the flue measurement section; the data processing module stores, analyzes and calculates the data collected by the differential pressure sensor and the bidirectional laser ranging module, and then sends the raw data and / or analysis and calculation results to the cloud and / or terminal devices.

[0064] The aforementioned data processing module can calculate the cross-sectional area Fs of the flue measurement end face of the reference method by measuring the lateral and longitudinal distances of each point in the flue using the bidirectional laser ranging module.

[0065] This application preferably sends measurement data and analysis results to an officially recognized cloud platform in real time, which can effectively ensure the accuracy and traceability of the data.

[0066] This invention relates to a velocity field coefficient calibration robot system, which can be used for flow calibration of large-diameter flues. It solves the problems of inaccurate positioning, low precision, difficult operation, lack of data traceability, and high safety risks inherent in existing manual flow calibration methods for large-diameter flues. In use, after dividing the flue into grid sections according to relevant technical specifications, a track matching the grid layout is preset. The velocity field coefficient calibration robot, equipped with a flow velocity reference probe and component compartment, is placed on the track. It can automatically run according to a preset program, automatically stopping and performing measurements at the center of the grid being measured, simultaneously processing, storing, and transmitting the data. After all grid measurements are completed, the velocity field coefficient calibration robot returns along the original track, stopping again at the center of each grid for re-measurement, and finally automatically returns to the return compartment to wait for further instructions. This achieves automated, double-repeated calibration of flue flow, ensuring the accuracy of the measurement data.

[0067] This invention utilizes a velocity field coefficient calibration robot to replace manual labor in calibrating the flow rate of large-diameter flues, achieving automation and intelligence in the calibration process. Precise track placement and robot-stationary parking solve the problem of inaccurate positioning during manual calibration, significantly improving measurement accuracy. The design incorporates visual sensors and rescue hooks, ensuring robot safety and convenient troubleshooting. The robot's data processing module enables digital acquisition, analysis, and transmission of measurement data, providing effective evidence for data traceability and eliminating the uncertainty of manual record management. The entire calibration process eliminates the need for personnel to work at heights or inside the flue, significantly reducing physical exertion and safety risks for workers, while also reducing manpower and equipment costs and improving the efficiency and effectiveness of calibration operations.

[0068] Suitable for on-site calibration of large-diameter flow meters, especially for emission monitoring in controlled emission enterprises, and particularly suitable for flue gas flow calibration in the field of carbon emission metering of thermal power units.

[0069] Any techniques not mentioned in this invention are based on existing technologies.

[0070] This invention relates to a velocity field coefficient calibration robot system, its installation structure, and calibration method. It enables automated and high-precision calibration of large-diameter flue gas flow rates, ensuring the accuracy, reliability, and traceability of measurement data, reducing operating costs and safety risks. It is particularly suitable for flue gas flow rate calibration in the field of carbon emission metering for thermal power units. Attached Figure Description

[0071] Figure 1 A schematic diagram of the mounting bracket layout (in the form of a rectangular grid).

[0072] Figure 2 This is a schematic diagram of the center of the mounting bracket (showing the center of each rectangular grid: the intersection of the center line of the width direction and the center line of the length direction of each rectangular grid);

[0073] Figure 3 A schematic diagram for calibrating the robot's motion trajectory using velocity field coefficients;

[0074] Figure 4 A front view of the robot and its track is used to calibrate the velocity field coefficients.

[0075] Figure 5 for Figure 4 View from direction A;

[0076] Figure 6 for Figure 4 View from direction B;

[0077] Figure 7 This is a front view of the return capsule;

[0078] Figure 8 This is a schematic diagram of a flow velocity reference probe.

[0079] Figure 9 This is an enlarged schematic diagram of the suspension drive unit;

[0080] In the diagram, 1-Fluorite; 2-Mounting bracket; 3-Railway; 301-First protrusion; 302-Second protrusion; 4-Return capsule; 5-Velocity field coefficient calibration robot; 6-Flow velocity reference probe; 61-Spherical measuring probe (measuring end); 62-Connecting flange; 7-Suspension drive device; 701-Mounting block; 702-Lower roller; 703-Side roller; 704-Upper roller; 8-Component compartment; 9-Rescue buckle; 10-Vision sensor; 11-Automatic hatch. Detailed Implementation

[0081] To better understand the present invention, the following embodiments further illustrate the content of the present invention, but the content of the present invention is not limited to the following embodiments.

[0082] The directional terms in this application, such as "center," "vertical," "horizontal," "length," "width," "thickness," "upper," "lower," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," are based on the appendix. Figure 4 The orientation or positional relationship shown or in use is for the purpose of describing this application only, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0083] Example 1

[0084] like Figure 1-9 As shown, a velocity field coefficient calibration robot working system includes a velocity field coefficient calibration robot, a suspension drive device, a track, and a return capsule;

[0085] The velocity field coefficient calibration robot includes a component compartment and a flow velocity reference probe. The flow velocity reference probe is detachably mounted on the component compartment. The distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is not less than 20cm. The flow velocity reference probe is an S-shaped Pitot tube adapted to the measuring wall.

[0086] The track is spiral-shaped; the head end of the track extends into the return capsule and connects with it.

[0087] The component compartment of the velocity field coefficient calibration robot is connected to the track via a suspension drive device. The velocity field coefficient calibration robot can run along the length of the track under the drive of the suspension drive device, or it can enter the return capsule.

[0088] The above system is suitable for standardized grid calibration of large-diameter flues, with a simple structure and high accuracy.

[0089] Example 2

[0090] Based on Example 1, the following improvements were made: A differential pressure sensor, a data processing module, and a bidirectional laser ranging module are also installed on the component compartment; both the differential pressure sensor and the bidirectional laser ranging module are connected to the data processing module; the differential pressure sensor is also connected to a flow velocity reference probe to collect the differential pressure signal transmitted by the flow velocity reference probe and transmit it to the data processing module to obtain the average flow velocity Vs of the flue measurement section; the bidirectional laser ranging module is used to obtain the lateral and longitudinal distances inside the flue and transmit them to the data processing module to calculate the average length and average width of the measurement section, thus obtaining the cross-sectional area Fs of the flue measurement section; the data processing module is used for real-time data acquisition, analysis, storage, and transmission. In this example, the differential pressure sensor uses the Rosemount 3051 series differential pressure transmitter manufactured by Emerson; the data processing module uses the STM32F407-STD industrial control board manufactured by Hard Rock Technology; and the bidirectional laser ranging module uses the MAGPIE Saber X laser rangefinder.

[0091] Using the above scheme, the cross-sectional area Fs of the reference method measurement section can be accurately obtained. According to the provisions of the "G.4 Field Detection Method of Flue Gas Velocity Monitoring Unit" section in standard GB / T 45869, the velocity field coefficient can be calculated.

[0092] Example 3

[0093] Based on Example 2, the following improvements were made: To extend the service life, a temperature control module is also provided on the component compartment, which is connected to the data processing module. The temperature control module is used to prevent overheating of the components inside the return compartment, maintain the normal operation of the robot's internal components, and transmit temperature data to the data processing module. The temperature control module can be either an electrically controlled temperature control module or a simple dry ice pack temperature control module. This example uses a dry ice pack temperature control module, which includes a dry ice pack for cooling and a temperature sensor (in this example, a thermistor NTC 10K / 3950 manufactured by Minchuang Electronics is used). The temperature sensor can transmit the real-time temperature of the component compartment to the data processing module to monitor the temperature and the usage status of the dry ice pack. It is simple, convenient, space-saving, and low-cost. Each module is independently packaged and waterproofed and corrosion-resistant, making it suitable for the harsh working environment inside the flue.

[0094] Example 4

[0095] Based on Example 3, the following improvements were made: For greater convenience and practicality, the system further includes a vision sensor (in this example, a RER-USB48MP01 camera manufactured by Realtek is used). The vision sensor is located on the outer wall of the component compartment and is connected to the data processing module. The vision sensor can perceive real-time environmental images inside the flue and transmit them to the data processing module. The data processing module processes the images and sends them to the operator, facilitating real-time monitoring of the internal environment of the flue. Furthermore, when the vision sensor detects an insurmountable obstacle ahead, the data processing module stops the component compartment's movement relative to the track and issues an alarm signal, reducing or preventing robot malfunctions and damage. The vision sensor, installed on the front and sides in the robot's direction of movement, employs a high-temperature resistant and dust-proof lens design.

[0096] Example 5

[0097] Based on embodiment 4, the following improvements were made: the longitudinal section of the track is an "I" structure, one end of the track is provided with a first protrusion for connecting with the mounting bracket inside the flue, and the other end of the track is provided with a second protrusion;

[0098] The suspension drive unit includes a drive motor, a brake mechanism, a mounting block, a lower roller, side rollers, and an upper roller; such as Figure 4 As shown, the mounting block is connected to the component compartment on one side and has a convex-shaped travel groove on the other side. The lower roller is installed at the bottom of the travel groove, the upper roller is installed at the two shoulders of the travel groove, and the side rollers are installed on both sides of the travel groove located below the two shoulders.

[0099] The second protrusion on the track matches the travel groove of the mounting block and forms a rolling engagement with the lower roller, side roller and upper roller. This ensures the stability of operation and allows the robot to be reliably suspended on the track in any posture, effectively resisting the impact of flue gas in the flue.

[0100] The drive motor is connected to the lower roller and is used to drive the lower roller to rotate; the brake mechanism is connected to the lower roller or the drive motor and is used to brake the lower roller to control its rotation.

[0101] The power output end of the aforementioned drive motor is connected to the lower roller drive to drive the lower roller to rotate and enable the robot to walk; the brake mechanism is set corresponding to the lower roller and forms a braking engagement with the lower roller or the drive motor shaft; when the brake mechanism is activated, it can apply braking force to the lower roller or the drive motor shaft to limit or prevent the roller from rotating, thereby achieving braking and enabling the robot to stop quickly and stably at the center of the grid, meeting the requirements of fixed-point measurement.

[0102] Example 6

[0103] Based on Example 5, the following improvements were made: For ease of use and arrangement, the track is a rectangular spiral shape, and the turning points of the track use a circular arc transition with a radius of not less than 10cm to avoid problems such as jamming or derailment when the robot turns, ensuring smooth operation. To extend the service life of the track, it is made of corrosion-resistant materials or has an anti-corrosion coating on its outer wall. In this example, polytetrafluoroethylene (PTFE) is used as the corrosion-resistant material to prepare the track, which is lightweight and durable.

[0104] Example 7

[0105] Based on Example 6, the following improvements were made: In order to improve the accuracy of the measurement, the flow velocity reference probe in this example is a three-dimensional Pitot tube, and the distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is 62cm.

[0106] Example 8

[0107] Based on Example 7, the following improvements were made: For ease of use, the flow velocity reference probe is a retractable and rotatable adjustable structure, which can accurately adjust the measurement distance and angle according to the grid center position. The aforementioned retractable and rotatable adjustable structure can be directly adopted from existing mature technologies, and this application has not made any special improvements in this regard, so it will not be described in detail here.

[0108] Example 9

[0109] Based on Embodiment 7 or 8, the following improvements were made: To facilitate rescue in case of failure, rescue buckles are provided around the outer wall of the component compartment. When the velocity field coefficient calibration robot stops due to failure, the operator can load the rescue robot onto the track, connect the traction mechanism of the rescue robot to the rescue buckle of the failed robot, and use the rescue robot to drag the failed velocity field coefficient calibration robot into the return compartment for repair. This eliminates the need for personnel to enter the flue to work, reducing the safety risks of fault handling.

[0110] Example 10

[0111] In the above examples, the installation structure of the velocity field coefficient calibration robot working system is as follows: it is installed on the flue.

[0112] The flue is equipped with mounting brackets, and the track is mounted on the mounting brackets; the return capsule is located outside the flue; the head end of the track extends out of the flue and into and connects to the return capsule;

[0113] The velocity field coefficient calibration robot runs from the head end to the tail end of the track. The measuring end of the flow velocity reference probe passes through all the measuring points arranged in a grid method in the flue. The number of measuring points meets the requirements of GB / T 16157.

[0114] Example 11

[0115] Unlike Example 10, in this example, the head end of the track extends into the reentry capsule but is not connected to the inner wall of the reentry capsule. The reentry capsule is directly installed on the outer wall of the flue.

[0116] Example 12

[0117] Based on Embodiment 10 or 11, the following improvements were made: To facilitate the installation of the track and the control of the measurement position, the mounting bracket is a rectangular grid of equal area, that is, the mounting bracket is a grid composed of rectangular grids (rectangular borders) of equal area; the track is installed on the mounting bracket in a rectangular spiral shape, the track passes through each rectangular grid of the mounting bracket, the track is offset from the center of each rectangular grid, and is parallel to the line connecting the centers of each rectangular grid; the velocity reference probe is perpendicular to the track direction. When the velocity field coefficient calibration robot walks from the head end to the end end of the track or from the end end to the head end, the measuring end of the velocity reference probe passes through the center of each rectangular grid.

[0118] Example 13

[0119] Based on Example 12, the following improvements were made: To minimize measurement time and improve calibration efficiency, a rectangular tapering spiral shape is preferred for the track; the track's structure gradually spirals from the inside and outside of the flue towards the center from the beginning to the end. This spiral track design allows the robot to complete continuous measurements of all grids along a single track without frequent track changes or active steering, simplifying the drive mechanism and significantly improving calibration efficiency. The track and mounting bracket are staggered, not on the same cross-section, to prevent interference between the robot and the mounting bracket during operation.

[0120] Example 14

[0121] Based on Example 13, the following improvements were made: To facilitate maintenance, the return capsule is located at a position where there is a maintenance platform at the top edge or side wall edge of the flue; an entrance and exit are provided at the intersection of the track and the flue wall, and an automatic hatch is provided at the entrance and exit. The hatch is equipped with an elastic sealing gasket around its perimeter, which can seal the entrance and exit; the automatic hatch is equipped with a sensing module, and the automatic hatch automatically opens when the velocity field coefficient calibration robot approaches and automatically closes and seals after the velocity field coefficient calibration robot passes through. Specifically, it can be implemented with reference to existing sensor door technology.

[0122] A method for calibrating velocity field coefficients, implemented using the aforementioned mounting structure, includes the following steps:

[0123] 1) The velocity field coefficient calibration robot runs from the head end to the tail end of the track, and continuously measures in real time during the operation and / or stops at each measurement point to measure individually;

[0124] 2) The velocity field coefficient calibration robot runs from the tail end of the track to the head end, and continuously measures in real time during the operation and / or stops at each measurement point it passes to measure individually;

[0125] 3) Compare the measurement data obtained in steps 1) and 2). When the deviation of the data obtained by each measurement point in steps 1) and 2) is less than 5%, the average value of the data obtained by each measurement point in steps 1) and 2) is used as the calibration basis value. When the deviation of the data obtained by at least one measurement point in steps 1) and 2) is greater than or equal to 5%, repeat steps 1) and 2) until the deviation of the data obtained by each measurement point in steps 1) and 2) is less than 5%, and use the average value of the data obtained by each measurement point in steps 1) and 2) as the calibration basis value.

[0126] 4) After the measurement is completed, the velocity field coefficient calibration robot returns to the return capsule to wait for further instructions.

[0127] In step 3) above, when the data deviations obtained by each measurement point in steps 1) and 2) are all <5%, the average value of the data obtained by each measurement point in steps 1) and 2) is used as the basis for calculating the average flow velocity of the measuring end face by the reference method. Then, according to the provisions of the "G.4 Field Detection Method of Flue Gas Velocity Monitoring Unit" section in standard GB / T 45869, the velocity field coefficient is calculated.

[0128] Combining this application with mature existing technologies, the operating program of the aforementioned velocity field coefficient calibration robot can be pre-set according to the grid layout of the flue, supporting remote start, pause, and termination operations. Its measurement method is highly flexible, and three modes can be selected according to actual calibration needs: First, continuous real-time measurement during operation, with the flow velocity reference probe continuously collecting data as the robot runs along the track, suitable for dynamic monitoring of flue flow; Second, stopping at preset measurement point positions for individual measurement, with the robot stopping after reaching the center of each grid and collecting data again after the measurement data stabilizes, which is the preferred measurement mode and suitable for fixed-point calibration using the standard grid method; Third, a combination of the above two methods, with continuous measurement followed by re-measurement at the grid center position, taking into account both dynamic monitoring and fixed-point calibration needs.

[0129] During the measurements in steps 1) and 2) above, the differential pressure sensor collects the differential pressure signal transmitted by the flow velocity reference probe and transmits it to the data processing module to obtain the average flow velocity Vs of the flue measurement section; at the same time, the bidirectional laser ranging module measures the lateral and longitudinal distances of each point in the flue and transmits them to the data processing module to obtain the cross-sectional area Fs of the flue measurement section; the data processing module stores, analyzes and calculates the data collected by the differential pressure sensor and the bidirectional laser ranging module, and then sends the raw data and / or analysis and calculation results to the cloud and / or terminal devices.

[0130] The aforementioned data processing module can measure the lateral and longitudinal distances of various points within the flue using the bidirectional laser ranging module, obtain the average length and average width of the measured cross section, and then calculate the cross-sectional area Fs of the flue measurement end face of the reference method.

[0131] In this example, the measurement data and analysis results are sent to an officially recognized cloud platform in real time, which effectively ensures the accuracy and traceability of the data.

[0132] This example, combined with the velocity field coefficient calibration robot system of Embodiment 9, was used in a 1000MW coal-fired power unit to accurately calibrate the velocity field coefficient of multi-point Pitot tube flowmeters (the calibrated velocity field coefficient was 0.9895), significantly improving the accuracy of carbon emission flow measurement. The aforementioned device uses a velocity field coefficient calibration robot to replace manual labor in calibrating the flow in large-diameter flues, achieving automation and intelligence in the calibration process. Precise track layout and robot stationary positioning solve the problem of inaccurate positioning during manual calibration, greatly improving measurement accuracy. The design, incorporating visual sensors and rescue hooks, ensures the robot's operational safety and facilitates convenient fault handling. The robot's data processing module enables digital acquisition, analysis, and transmission of measurement data, providing effective evidence for data traceability and resolving the management uncertainties of manual recording. The entire calibration process eliminates the need for personnel to work at heights or inside the flue, significantly reducing physical exertion and safety risks for operators, while also reducing manpower and equipment costs and improving the efficiency and effectiveness of calibration operations.

Claims

1. A velocity field coefficient calibration robot work system characterized by: This includes a velocity field coefficient calibration robot, a track, and a return capsule; The velocity field coefficient calibration robot includes a component compartment and a flow velocity reference probe. The flow velocity reference probe is installed on the component compartment, and the distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is not less than 20cm. The track is spiral-shaped; the front end of the track extends into the return capsule. The component compartment of the velocity field coefficient calibration robot is connected to the track. The velocity field coefficient calibration robot can run along the length of the track or enter the return capsule.

2. The velocity field coefficient calibration robot working system according to claim 1, characterized in that: The component compartment is also equipped with a differential pressure sensor, a data processing module, and a two-way laser ranging module. Both the differential pressure sensor and the two-way laser ranging module are connected to the data processing module. The differential pressure sensor is also connected to a flow velocity reference probe to collect the differential pressure signal transmitted by the flow velocity reference probe and transmit it to the data processing module to obtain the average flow velocity Vs of the flue measurement section. The two-way laser ranging module is used to obtain the lateral and longitudinal distances inside the flue and transmit them to the data processing module to obtain the cross-sectional area Fs of the flue measurement section. The data processing module is used to collect, analyze, store, and transmit data in real time.

3. The velocity field coefficient calibration robot working system according to claim 2, characterized in that: The component compartment is also equipped with a temperature control module, which is connected to the data processing module. The temperature control module is used to prevent the components inside the return capsule from overheating, maintain the normal operation of the robot's internal components, and transmit temperature data to the data processing module. And / or, it also includes a vision sensor, which is located on the outer wall of the component compartment and is connected to the data processing module.

4. The velocity field coefficient calibration robot working system according to any one of claims 1-3, characterized in that: The component compartment of the velocity field coefficient calibration robot is connected to the track via a suspension drive device; The longitudinal section of the track is an "I" structure. One end of the track is provided with a first protrusion for connecting with the mounting bracket inside the flue, and the other end of the track is provided with a second protrusion. The suspension drive unit includes a drive motor, a brake mechanism, a mounting block, a lower roller, side rollers, and an upper roller; one side of the mounting block is connected to the component compartment, and the other side is provided with a U-shaped travel groove. The lower roller is installed at the bottom of the travel groove, the upper roller is installed at the two shoulders of the travel groove, and the side rollers are installed on both sides of the travel groove located below the two shoulders. The second protrusion on the track matches the travel groove of the mounting block and forms a rolling engagement with the lower roller, side roller and upper roller; The drive motor is connected to the lower roller and is used to drive the lower roller to rotate; the brake mechanism is connected to the lower roller or the drive motor and is used to brake the lower roller to control its rotation.

5. The velocity field coefficient calibration robot working system according to any one of claims 1-3, characterized in that: The track is rectangular spiral in shape, and the turning points of the track are transitioned by a circular arc with a radius of not less than 10cm. And / or, the track is made of corrosion-resistant material or has a corrosion-resistant coating on the outer wall of the track.

6. The velocity field coefficient calibration robot working system according to any one of claims 1-3, characterized in that: The flow rate reference probe can be any one of an S-type Pitot tube, an L-type Pitot tube, or a three-dimensional Pitot tube; And / or, the flow rate reference probe is detachably mounted on the component compartment; And / or, the distance between the measuring end of the flow velocity reference probe and any side wall of the component compartment is not less than 50cm; And / or, the flow rate reference probe is a retractable and rotatable adjustable structure; And / or, rescue latches are provided around the outer walls of the component compartment.

7. The velocity field coefficient calibration robot working system according to claim 6, characterized in that: The flow velocity reference probe is a three-dimensional pitot tube.

8. The mounting structure of the velocity field coefficient calibration robot working system according to any one of claims 1-7, characterized in that: Installed on the flue; The flue is equipped with mounting brackets, and the track is mounted on the mounting brackets; the return capsule is located outside the flue; the head end of the track extends out of the flue and into the return capsule; When the velocity field coefficient calibration robot runs from the head end to the tail end of the track, the measuring end of the flow velocity reference probe passes through all the measuring points arranged in a grid method in the flue, and the number of measuring points meets the requirements of GB / T 16157.

9. The installation structure according to claim 8, characterized in that: The mounting bracket is a rectangular grid of equal area; the track is mounted on the mounting bracket in a rectangular spiral shape, and the track passes through each rectangular grid of the mounting bracket. The track is offset from the center of each rectangular grid and is parallel to the line connecting the centers of each rectangular grid. When the velocity field coefficient calibration robot walks from the head end to the end end of the track or from the end end to the head end, the measuring end of the flow velocity reference probe passes through the center of each rectangular grid.

10. The mounting structure according to claim 8 or 9, characterized in that: The return capsule is located at the edge of the top or side wall of the flue where there is a maintenance platform; an entrance and exit are provided at the intersection of the track and the flue wall, and an automatic hatch is provided at the entrance and exit. The hatch is equipped with an elastic sealing gasket around its perimeter, which can seal the entrance and exit. The automatic hatch is equipped with a sensing module, which automatically opens when the velocity field coefficient calibration robot approaches and automatically closes and seals the hatch after the robot passes.

11. A method for calibrating velocity field coefficients, characterized in that: The installation structure described in any one of claims 8 to 10 is used to achieve the following steps: 1) The velocity field coefficient calibration robot runs from the head end to the tail end of the track, and continuously measures in real time during the operation and / or stops at each measurement point to measure individually; 2) The velocity field coefficient calibration robot runs from the tail end of the track to the head end, and continuously measures in real time during the operation and / or stops at each measurement point it passes to measure individually; 3) Compare the measurement data obtained in step 1) and step 2). When the deviation of the data obtained by each measurement point in step 1) and step 2) is less than 5%, the average value of the data obtained by each measurement point in step 1) and step 2) shall be used as the calibration basis value. When the data deviation obtained by at least one measurement point in steps 1) and 2) is ≥5%, repeat steps 1) and 2) until the data deviation obtained by each measurement point in steps 1) and 2) is <5%, and use the average value of the data obtained by each measurement point in steps 1) and 2) as the calibration basis value; 4) After the measurement is completed, the velocity field coefficient calibration robot returns to the return capsule to wait for further instructions.

12. The method for calibrating the velocity field coefficients according to claim 11, characterized in that: During steps 1) and 2), the differential pressure sensor collects the differential pressure signal transmitted by the flow velocity reference probe and transmits it to the data processing module to obtain the average flow velocity Vs of the flue measurement section; at the same time, the bidirectional laser ranging module measures the lateral and longitudinal distances of each point in the flue and transmits them to the data processing module to obtain the cross-sectional area Fs of the flue measurement section; the data processing module stores, analyzes and calculates the data collected by the differential pressure sensor and the bidirectional laser ranging module, and then sends the raw data and / or analysis and calculation results to the cloud and / or terminal devices.

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