A non-loss sensor for monitoring concentration of binary gas based on thermal principle

Abstract

This invention relates to the field of industrial Internet of Things (IIoT) information sensing technology, specifically disclosing a lossless sensor for monitoring binary gas concentration based on the thermal principle. The sensor includes: a detection channel, a heating element, a temperature detection element, a reference thermal path, a thermal excitation drive circuit, a status acquisition interface, a processor, a memory, and an IIoT communication interface. The thermal excitation drive circuit drives the heating element according to the basic thermal excitation state and the detected thermal excitation state. The temperature detection element acquires the detected thermal response signal, the reference thermal path outputs a reference thermal response signal, and the status acquisition interface receives the temperature, flow rate, or pressure status signals of the detection channel. The processor generates and corrects the thermal response characteristic values ​​and then calls the binary gas concentration calibration relationship to generate the concentration result. This invention binds thermal response differences, channel state, and operating status markers, ensuring that the concentration result has a corresponding detection state source and measurement record.

Description

Technical Field

[0001] This invention relates to the field of industrial Internet of Things (IoT) information sensing technology, and in particular to a lossless sensor for monitoring binary gas concentration based on the thermal principle. Background Technology

[0002] Industrial Internet of Things (IIoT) information sensing technology typically revolves around sensing, collecting, transmitting, calculating, storing, and displaying objects such as gas, temperature, pressure, flow rate, and equipment status at the production site. Sensors, field instruments, edge gateways, and servers transmit time-series data via wired buses or wireless links, and perform status identification based on sampled values, thresholds, calibration curves, and statistical records. Among these, traditional non-destructive sensors for monitoring binary gas concentration based on thermal principles refer to sensors that monitor the concentration of binary gas mixtures by observing their thermal conduction and diffusion characteristics in the detection chamber or flow channel. These sensors typically consist of a micro-heating element, a thermistor or temperature sensing element, a gas channel, a constant-temperature or constant-power drive circuit, an analog-to-digital converter, and a processor. They collect changes in temperature, resistance, voltage, or power before and after heating, convert these changes into gas component concentrations through calibration relationships, and transmit the concentration values ​​to a gateway, controller, or host computer via a local interface or industrial communication link.

[0003] In thermal binary gas concentration monitoring, the concentration of the gas to be measured is converted from a single thermal response or a fixed calibration relationship after passing through the detection area. There is insufficient correlation between the working status of the heating element, the temperature detection sequence, and the state of the gas flow channel. When the sensor itself experiences thermal drift or environmental thermal disturbances enter the measurement link, the concentration results lack records corresponding to the thermal excitation state and operating state. The measured values ​​received by the industrial IoT node are difficult to distinguish between changes in gas composition, changes in detection conditions, and changes in equipment operating status, and the traceability of measurement records is limited. Summary of the Invention

[0004] The purpose of this invention is to provide a non-destructive sensor for monitoring binary gas concentration based on the thermal principle. This sensor allows the binary gas to pass through the detection channel without damage. It correlates the thermal excitation state, the detection thermal response signal, the reference thermal response signal, the detection channel state signal, and the industrial IoT output record to solve the problem of insufficient correlation between the concentration conversion basis and the thermal excitation state, the gas channel state, and the equipment operating state in traditional thermal binary gas concentration monitoring.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a non-destructive sensor for monitoring binary gas concentration based on the thermal principle, comprising a detection channel for the non-destructive passage of binary gas, a heating element and a temperature detection element corresponding to the detection channel, a reference thermal path for generating a reference thermal response signal, a thermal excitation drive circuit, a status acquisition interface, a processor, a memory, and an industrial IoT communication interface. The thermal excitation drive circuit is connected to the heating element and outputs drive signals to the heating element according to the basic thermal excitation state and the detected thermal excitation state. The temperature detection element acquires the detected thermal response signals under different thermal excitation states, and the reference thermal path outputs a reference thermal response signal. The status acquisition interface receives temperature, flow rate, or pressure status signals from the detection channel. The memory stores binary gas concentration calibration relationships and status correction rules. The processor generates thermal response feature values ​​based on the difference between the detected thermal response signal and the reference thermal response signal, and after correcting the thermal response feature values ​​in conjunction with the status signals, calls the binary gas concentration calibration relationship to generate the concentration result. When the difference between the detected thermal response signal and the reference thermal response signal meets the preset operating range, the processor marks and binds the concentration result, sampling time, thermal excitation state, and operating status as a measurement record, and outputs it through the industrial IoT communication interface.

[0006] Furthermore, the process of the sensor forming a binary gas non-destructive testing channel and a reference thermal path includes: setting the detection channel as an inlet section, a heat exchange section, and an outlet section connected in sequence, so that the binary gas enters the heat exchange section from the inlet section and exits through the outlet section; setting the heating element and temperature detection element corresponding to the heat exchange section, so that the temperature detection element obtains the detection thermal response signal under different thermal excitation states within the heat exchange section; setting the reference thermal path at a position adjacent to the heat exchange section but not in direct contact with the binary gas, and forming a reference thermal response signal during the output of the drive signal from the thermal excitation drive circuit to the heating element; the status acquisition interface receives the temperature, flow rate, or pressure status signals corresponding to the inlet section, heat exchange section, or outlet section; and the processor generates the correction basis for the thermal response characteristic value after corresponding the status signal with the sampling time of the detection thermal response signal.

[0007] Furthermore, the process of switching the thermal excitation state by the thermal excitation drive circuit includes: after the binary gas enters the heat exchange section, the thermal excitation drive circuit first outputs the drive signal of the basic thermal excitation state, and the temperature detection element collects the basic thermal response signal; when the change amplitude of the basic thermal response signal within the preset sampling window meets the stability judgment range, the thermal excitation drive circuit switches to the detection thermal excitation state and outputs the detection drive signal; when the change amplitude of the basic thermal response signal within the preset sampling window does not meet the stability judgment range, the processor delays the switching of the detection thermal excitation state and rereads the status signal received by the status acquisition interface, and the temperature detection element obtains the detection thermal response signal in the detection thermal excitation state.

[0008] Furthermore, the process of the processor generating thermal response feature values ​​includes: extracting the settling time of the basic thermal response signal within the sampling window corresponding to the basic thermal excitation state; extracting the temperature change rate or compensation power change of the detected thermal response signal within the sampling window corresponding to the detected thermal excitation state; using the settling time of the basic thermal response signal as the sampling judgment criterion; and using the temperature change rate or compensation power change of the detected thermal response signal as the concentration-sensitive quantity. When the sampling judgment criterion meets the preset sampling conditions, the processor generates thermal response feature values ​​based on the concentration-sensitive quantity. When the sampling judgment criterion does not meet the preset sampling conditions, the processor stops using the detected thermal response signal within the current sampling window to generate thermal response feature values.

[0009] Furthermore, the processor's process of processing the difference between the detected thermal response signal and the reference thermal response signal includes: obtaining the response amplitude of the detected thermal response signal under the detected thermal excitation state and the response amplitude of the reference thermal response signal within the same sampling period, and forming a thermal path difference quantity according to the difference or ratio of response amplitudes; when the thermal path difference quantity falls within a preset operating range, the processor uses the thermal path difference quantity as input to generate thermal response feature values; when the thermal path difference quantity does not fall within the preset operating range, the processor generates an operating status flag corresponding to the current sampling period.

[0010] Furthermore, the process of the processor correcting the thermal response characteristic value by combining the status signal includes: the status acquisition interface receives the temperature, flow rate or pressure status signal of the detection channel during the same sampling period when the temperature detection element acquires the detected thermal response signal, and establishes a correspondence between the status signal and the detected thermal response signal according to the sampling time; when the status signal is within the state range defined by the status correction rule, the processor generates a correction factor according to the status correction rule, and uses the correction factor to correct the thermal response characteristic value; when the status signal exceeds the state range defined by the status correction rule, the processor stops using the thermal response characteristic value corresponding to the current sampling period to generate the concentration result, and generates an operating status mark.

[0011] Furthermore, the process by which the processor calls the binary gas concentration calibration relationship to generate the concentration result includes: determining the calibration relationship calling conditions based on the corrected thermal response characteristic value, and using the temperature, flow rate, or pressure status signal of the detection channel as the verification basis for the calibration relationship calling conditions; when the calibration relationship calling conditions match the gas type identifier and state range in the binary gas concentration calibration relationship, the processor calls the corresponding binary gas concentration calibration relationship and generates the concentration result; when the calibration relationship calling conditions do not match the gas type identifier or state range in the binary gas concentration calibration relationship, the processor generates an operating status flag corresponding to the calibration relationship calling failure.

[0012] Furthermore, the process by which the processor binds the concentration result, sampling time, thermal excitation state, and operating status marker into a measurement record includes: using the sampling time at which the temperature sensing element obtains the detected thermal response signal as the sampling time, and establishing a correspondence between the concentration result and the sampling time; writing the determination results of whether the basic thermal excitation state, the detected thermal excitation state, and the difference between the detected thermal response signal and the reference thermal response signal meet the preset operating range into the operating status marker; when the concentration result, sampling time, thermal excitation state, and operating status marker are all written in their corresponding positions, the processor generates a measurement record; when any corresponding writing is incomplete, the processor generates a measurement record with a missing record status.

[0013] Furthermore, the process of outputting measurement records through the industrial IoT communication interface includes: the processor writes the measurement records into the upload queue according to the sampling time sequence, and verifies the correspondence between the concentration result, thermal excitation state, and operating status flag in the measurement record before writing; when the correspondence of the measurement records meets the upload conditions, the industrial IoT communication interface outputs the measurement records to the industrial IoT nodes; when the correspondence of the measurement records does not meet the upload conditions, the processor retains the measurement records and generates an operating status flag corresponding to the upload verification failure.

[0014] Furthermore, the process of the processor confirming the output of measurement records in the upload queue includes: after the industrial IoT communication interface outputs the measurement record to the industrial IoT node, the processor receives the reception confirmation information corresponding to the measurement record and associates the reception confirmation information with the sampling time; when the reception confirmation information meets the consistency conditions with the concentration result, thermal excitation state, and operating status flag in the measurement record, the processor marks the measurement record as output; when the reception confirmation information is not returned within the preset confirmation time, or when the reception confirmation information does not meet the consistency conditions with the concentration result, thermal excitation state, and operating status flag in the measurement record, the processor retains the measurement record in the upload queue and generates an operating status flag corresponding to the output confirmation failure.

[0015] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: By configuring heating elements and temperature sensing elements within the detection channel, and having the thermal excitation drive circuit output drive signals according to the basic thermal excitation state and the detected thermal excitation state, detection thermal response signals under multiple thermal excitation states can be obtained. A reference thermal path forms a reference thermal response signal. The processor generates thermal response characteristic values ​​based on the difference between the detected thermal response signal and the reference thermal response signal. After correction by combining the temperature, flow rate, or pressure state signals of the detection channel, the binary gas concentration calibration relationship is invoked to make the concentration result correspond to the heat transfer difference and the channel state. The concentration result, sampling time, thermal excitation state, and operating status are bound as measurement records and output, so that the measurement values ​​received by the industrial IoT node have a corresponding state source. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart of the lossless monitoring process for thermal binary gas concentration of the present invention; Figure 2 This is a schematic diagram of the detection channel and reference thermal path structure of the present invention; Figure 3 This is a timing diagram of thermal excitation state switching and thermal response sampling in this invention; Figure 4 This is a data flow diagram for the correction and calibration of thermal response characteristic values ​​in this invention; Figure 5 This is a schematic diagram illustrating the upload and output confirmation status of measurement records in this invention. Detailed Implementation

[0018] The specific embodiments of the present invention are described below with reference to the accompanying drawings. The descriptions in the subsequent embodiments are used to explain the technical solutions already defined in the claims and the invention content, and are not intended to introduce new technical lines outside the claims. In the subsequent embodiments, the detection channel, heating element, temperature detection element, reference thermal path, thermal excitation drive circuit, status acquisition interface, processor, memory, and industrial IoT communication interface have the same meaning as the objects with the same names in the claims and the invention content. Since the preceding claims and the invention content do not assign specific numerical labels to each entity component, the subsequent embodiments and accompanying reference text do not assign separate component numerical labels to the above components. If it is necessary to distinguish components in the figures, only the component name, data name, status name, or process node name is used for identification. The drawing numbers are only used to identify the drawings. Thermal excitation status, sampling time, preset sampling conditions, preset operating interval, status range, upload conditions, and consistency conditions are all pre-configured or engineering conditions defined by corresponding rules in the memory, and do not represent specific values, ranges, or performance indicators.

[0019] Please see Figures 1 to 5This embodiment provides a non-destructive sensor for monitoring binary gas concentration based on thermal principles, applied in industrial IoT information sensing scenarios for thermal detection of binary gas concentration. The sensor includes a detection channel for the non-destructive passage of binary gas, a heating element and a temperature sensing element corresponding to the detection channel, a reference thermal path for generating a reference thermal response signal, a thermal excitation drive circuit, a status acquisition interface, a processor, a memory, and an industrial IoT communication interface. The detection channel receives the binary gas and allows it to pass through a heat exchange area without consumption or reaction conversion. The heating element provides heat input to the corresponding area of ​​the detection channel when the thermal excitation drive circuit outputs a drive signal. The temperature sensing element acquires detection thermal response signals related to gas heat transfer under different thermal excitation states. The reference thermal path generates a reference thermal response signal in the thermal environment adjacent to the detection thermal path, enabling the processor to distinguish thermal path differences related to the detection thermal response signal. The status acquisition interface receives temperature, flow rate, or pressure status signals from the detection channel. The memory stores binary gas concentration calibration relationships, state correction rules, thermal excitation control conditions, preset sampling conditions, preset operating ranges, and upload conditions. The processor coordinates thermal excitation driving, thermal response acquisition, difference processing, state correction, concentration conversion, and measurement record output. The industrial IoT communication interface sends measurement records to industrial IoT nodes.

[0020] In terms of sensor structure, the detection channel includes an inlet section, a heat exchange section, and an outlet section connected in sequence. The binary gas enters the detection channel through the inlet section, contacts the detection area corresponding to the heating element and temperature sensing element through the heat exchange section, and then exits the detection channel through the outlet section. This flow direction ensures that the gas continues to flow as the measured gas after passing through the detection area, without being absorbed, consumed, or transformed during the detection process. Both the heating element and the temperature sensing element are positioned corresponding to the heat exchange section, enabling the temperature sensing element to obtain the detection thermal response signal affected by the thermal excitation state within the heat exchange section. A reference thermal path is positioned adjacent to the heat exchange section but not in direct contact with the binary gas; the reference thermal path and the heat exchange section are located within the same sensor body. During the output of the drive signal from the thermal excitation drive circuit to the heating element, the reference thermal path generates a reference thermal response signal. This reference thermal response signal does not directly represent the binary gas concentration but serves as a comparison object for subsequent difference processing of the detection thermal response signal.

[0021] When the sensor starts and enters the measurement process, the processor first reads the configuration content corresponding to the binary gas type, thermal excitation state, sampling window, and state correction rules from the memory. Under the processor's control, the thermal excitation drive circuit outputs a drive signal for the basic thermal excitation state. The heating element operates according to this drive signal, and the temperature detection element acquires the basic thermal response signal under the basic thermal excitation state. The basic thermal response signal reflects the thermal changes in the detection channel before it enters the sampleable stage. The processor reads the amplitude of the basic thermal response signal within a preset sampling window and compares this amplitude with the stability judgment range. When the amplitude of the basic thermal response signal within the preset sampling window meets the stability judgment range, the processor controls the thermal excitation drive circuit to switch from the basic thermal excitation state to the detection thermal excitation state. When the amplitude of the basic thermal response signal within the preset sampling window does not meet the stability judgment range, the processor delays the switching to the detection thermal excitation state and rereads the state signal received by the state acquisition interface, allowing the state signal to re-participate in the judgment of the detection timing.

[0022] Under the detected thermal excitation state, the thermal excitation drive circuit outputs a detection drive signal to the heating element. Under the action of the detection drive signal, the heating element generates a heat input related to the binary gas heat transfer, and the temperature detection element acquires the detected thermal response signal. The detected thermal response signal can reflect signal states related to binary gas heat transfer, such as the rate of temperature change, steady-state temperature difference, or change in compensation power. The processor extracts the settling time of the basic thermal response signal within the sampling window corresponding to the basic thermal excitation state, and extracts the rate of temperature change or change in compensation power of the detected thermal response signal within the sampling window corresponding to the detected thermal excitation state. The settling time of the basic thermal response signal serves as the sampling judgment criterion, and the rate of temperature change or change in compensation power of the detected thermal response signal serves as the concentration-sensitive quantity. When the sampling judgment criterion meets the preset sampling conditions, the processor generates thermal response feature values ​​based on the concentration-sensitive quantity. When the sampling judgment criterion does not meet the preset sampling conditions, the processor stops using the detected thermal response signal within the current sampling window to generate thermal response feature values, preventing the thermal response state within the current sampling window from directly entering concentration conversion.

[0023] During the processing of the reference thermal response signal, the processor acquires the response amplitude of the detected thermal response signal under the detected thermal excitation state and the response amplitude of the reference thermal response signal within the same sampling period, and forms a thermal path difference quantity according to the difference or ratio of response amplitudes. The response amplitude difference is used to characterize the absolute difference between the detected thermal path and the reference thermal path, and the response amplitude ratio is used to characterize the relative change of the detected thermal path relative to the reference thermal path. The processor does not directly use a single detected thermal response signal as the concentration conversion input, but uses the thermal path difference quantity as one of the bases for generating thermal response feature values. When the thermal path difference quantity falls within a preset operating range, the processor uses the thermal path difference quantity as the input for generating thermal response feature values. When the thermal path difference quantity does not fall within the preset operating range, the processor generates an operating status flag corresponding to the current sampling period. The operating status flag indicates that the difference between the detected thermal response signal and the reference thermal response signal within this sampling period does not meet the condition for entering the normal conversion.

[0024] During the processing of the flow channel status signal, the status acquisition interface receives the temperature, flow rate, or pressure status signals of the detected flow channel within the same sampling period as the temperature sensing element acquires the detected thermal response signal. The processor establishes a correspondence between the status signal and the detected thermal response signal according to the sampling time, using the status signal as the timing matching basis for correcting the thermal response feature value. After the status signal enters the processor, the processor queries the status correction rules in the memory and compares the status signal with the status range defined by the status correction rules. When the status signal is within the status range defined by the status correction rules, the processor generates a correction factor according to the status correction rules and uses the correction factor to correct the thermal response feature value. The correction factor is used to reflect the direction of the influence of the detected flow channel status on the heat transfer response, so that the corrected thermal response feature value can correspond to the flow channel status within the current sampling period. When the status signal exceeds the status range defined by the status correction rules, the processor stops using the thermal response feature value corresponding to the current sampling period to generate the concentration result and generates an operating status flag.

[0025] During the concentration result generation process, the processor determines the calibration relationship calling conditions based on the corrected thermal response characteristic values ​​and uses the temperature, flow rate, or pressure status signals of the detection channel as the verification basis for the calibration relationship calling conditions. The binary gas concentration calibration relationships stored in the memory include calling rules corresponding to gas type identifiers and state intervals. The processor matches the calibration relationship calling conditions with the gas type identifiers and state intervals in the binary gas concentration calibration relationships. When the calibration relationship calling conditions match the gas type identifiers and state intervals, the processor calls the corresponding binary gas concentration calibration relationship and generates the concentration result based on the corrected thermal response characteristic values. When the calibration relationship calling conditions do not match the gas type identifiers or state intervals, the processor does not output the concentration result generated by the calling conditions, but instead generates a running status flag corresponding to the calibration relationship call failure. Therefore, the concentration result generation process depends not only on the thermal response characteristic values ​​but also on the channel status and the calibration relationship calling conditions.

[0026] During the measurement record generation process, the processor uses the sampling time of the detected thermal response signal obtained by the temperature sensing element as the sampling time and establishes a correspondence between the concentration result and the sampling time. The processor also writes the baseline thermal excitation state, the detected thermal excitation state, and the judgment result of whether the difference between the detected thermal response signal and the reference thermal response signal meets the preset operating range into the operating status flag. The measurement record includes the concentration result, sampling time, thermal excitation state, and operating status flag. The concentration result represents the output of the binary gas concentration conversion; the sampling time identifies the temporal position of the detected thermal response signal; the thermal excitation state identifies the driving state corresponding to the concentration result; and the operating status flag identifies the state of the detected thermal response signal, the reference thermal response signal, the status signal, or the calibration relationship call condition within the current sampling period. When the concentration result, sampling time, thermal excitation state, and operating status flag are all written in their corresponding positions, the processor generates a measurement record. When any corresponding writing is incomplete, the processor generates a measurement record with missing record states, enabling industrial IoT nodes to distinguish between complete records and missing record states based on the measurement record.

[0027] During the Industrial Internet of Things (IIoT) output process, the processor writes measurement records to the upload queue in chronological order of sampling time. The upload queue temporarily stores measurement records to be output to the IIoT node. Before writing or outputting, the processor verifies the correspondence between concentration results, thermal excitation states, and operating status markers in the measurement records. This correspondence confirms whether the concentration results at the same sampling time match the corresponding thermal excitation states and operating status markers. When the correspondence of the measurement records meets the upload conditions, the IIoT communication interface outputs the measurement records to the IIoT node. When the correspondence of the measurement records does not meet the upload conditions, the processor retains the measurement records and generates an operating status marker corresponding to the upload verification failure. This upload process ensures that the measurement records already contain the state source corresponding to the detection state before entering the IIoT node.

[0028] During the output confirmation process, after the industrial IoT communication interface outputs a measurement record to the industrial IoT node, the processor receives the reception confirmation information corresponding to the measurement record and maps this information to the sampling time. The reception confirmation information characterizes the industrial IoT node's reception status of the measurement record, while the sampling time establishes a correspondence between the reception confirmation information and the specific measurement record. When the reception confirmation information meets the consistency conditions with the concentration result, thermal excitation state, and operating status marker in the measurement record, the processor marks the measurement record as output. When the reception confirmation information does not return within the preset confirmation time, or when the reception confirmation information does not meet the consistency conditions with the concentration result, thermal excitation state, and operating status marker in the measurement record, the processor retains the measurement record in the upload queue and generates an operating status marker corresponding to the output confirmation failure. Thus, the measurement record forms an output status closed loop between the sensor and the industrial IoT node.

[0029] In this embodiment, the basic thermal excitation state and the detected thermal excitation state are not for the consumption of the binary gas, but rather to enable the thermal transfer response of the binary gas in the detection channel to form comparable signal states at different driving stages. The reference thermal path does not participate in the binary gas flow process, but is located within the same sensor body as the detection thermal path, and can form a reference thermal response signal corresponding to the detected thermal response signal. The processor uses the difference between the detected thermal response signal and the reference thermal response signal as the basis for generating thermal response feature values, and further incorporates temperature, flow rate, or pressure state signals obtained from the state acquisition interface for correction. Through this structure and processing relationship, the thermal detection process forms a technical link from thermal excitation input, detected thermal response sampling, reference thermal response comparison, state signal correction, calibration relationship invocation, measurement record binding to industrial IoT output.

[0030] In this embodiment, the processor performs step-by-step judgments on sampling status, thermal path difference, status range, calibration relationship call, record writing, upload conditions, and received confirmation information. Each judgment step has corresponding input objects, comparison objects, judgment conditions, and output status. The input object for sampling status is the basic thermal response signal, the comparison object is the stable judgment range, and the output status is whether switching to the detection thermal excitation state is allowed or the switching is delayed. The input objects for thermal path difference are the detection thermal response signal and the reference thermal response signal, the comparison object is the preset operating range, and the output status is the input of thermal response feature value or the operating status flag. The input object for status correction is the temperature, flow rate, or pressure status signal, the comparison object is the status range defined by the status correction rule, and the output status is the correction factor or the operating status flag. The input objects for calibration relationship call are the corrected thermal response feature value and status signal, the comparison object is the gas type identifier and the status range, and the output status is the concentration result or the calibration relationship call failure flag. The input objects for the measurement record output are concentration result, sampling time, thermal excitation status and running status flag. The comparison objects are upload conditions and consistency conditions. The output status is output status or output confirmation failure flag.

[0031] In this embodiment, the binary gas concentration calibration relationship and state correction rules stored in the memory are used by the processor during operation, and it is not required to fix specific values ​​or specific entries in the embodiment. The binary gas concentration calibration relationship can be configured according to gas type identification and state range, and the processor selects the corresponding relationship according to the calibration relationship calling conditions when calling it. The state correction rule can be configured according to the temperature, flow rate or pressure state signal of the detection channel, and the processor generates a correction factor after the state signal enters the state range. The preset sampling conditions, preset operating range, upload conditions and consistency conditions are all limited by the rules pre-configured in the memory and serve as the basis for judgment during processor operation. This setting makes each judgment rule have a clear storage source and calling path, while not fixing specific parameter values ​​as a necessary limitation of the embodiment.

[0032] In this embodiment, the detected thermal response signal, reference thermal response signal, status signal, thermal response feature value, correction factor, concentration result, sampling time, thermal excitation state, operating status marker, measurement record, upload queue, and received confirmation information all have clearly defined data flow directions. The detected thermal response signal is acquired by the temperature detection element and sent to the processor; the reference thermal response signal is formed by the reference thermal path and sent to the processor; and the status signal is received by the status acquisition interface and sent to the processor. The processor generates a thermal response feature value based on the difference between the detected thermal response signal and the reference thermal response signal, and then combines it with the status signal to generate a corrected thermal response feature value. Subsequently, it calls the binary gas concentration calibration relationship to generate the concentration result. The concentration result is bound to the sampling time, thermal excitation state, and operating status marker as a measurement record. After the measurement record enters the upload queue, it is output to the industrial IoT node through the industrial IoT communication interface. The received confirmation information is returned to the processor to confirm the output status of the measurement record. This closed-loop data flow ensures that each measurement record can be associated with the thermal excitation state, sampling time, and operating status marker.

[0033] In this embodiment, the running status marker does not replace the concentration result, but rather participates in record binding as a status source field in the measurement record. The running status marker can correspond to states such as thermal path difference not falling within a preset running range, status signal exceeding the state range defined by the state correction rule, calibration relationship call failure, record missing, upload verification failure, or output confirmation failure. The processor generates a running status marker when the corresponding condition occurs and associates the running status marker with the sampling time. For measurement records that meet the concentration conversion and upload conditions, the running status marker is used to describe the thermal excitation state and running state corresponding to the measurement record. For cases where the concentration conversion, record writing, upload, or output confirmation conditions are not met, the running status marker is used to describe the processing status of the measurement record or the corresponding record in the upload queue. Through this marking method, the measurement values ​​received by the industrial IoT node have a corresponding detection status source.

[0034] In this embodiment, the sensor's non-destructive detection characteristic is reflected in the continuous flow relationship of the binary gas through the inlet section, heat exchange section, and outlet section. A heating element provides heat input to the heat exchange section, and a temperature sensing element collects the detection thermal response signal formed by the influence of gas heat transfer. A reference thermal path forms a reference thermal response signal that does not directly contact the binary gas. The processor performs concentration conversion based on the thermal response difference and state signal. The binary gas participates in the measurement process only as a heat transfer medium within the detection channel, without participating in concentration measurement through reaction, absorption, or sampling consumption. This detection relationship makes the sensor suitable for connection to industrial IoT nodes to generate gas concentration measurement records with state-based information.

[0035] The specific structure, process, field status, processing order, judgment conditions, parameter source, data flow, component cooperation, communication connection relationship, and measurement record binding method described in this embodiment are used to illustrate the feasible implementation of the present invention within the scope of the original disclosure, and should not limit the present invention to the specific expressions listed in this embodiment. Without departing from the scope of the claims and the original disclosure, any equivalent substitutions, equivalent modifications, equivalent combinations, order adjustments, module-to-module replacements, equivalent changes in field names, equivalent connection of the executing entity, or equivalent changes in the carrier form that can be conceived by those skilled in the art should fall within the scope of protection of this patent; however, they should not be extended to unclaimed topics, nor should the substantive correspondence of the technical objects be changed through changes in the names of the figures, node text, or reference numerals.

Claims

1. A lossless sensor for monitoring binary gas concentration based on the thermal principle, characterized in that, include: The system includes a detection channel for the non-destructive passage of binary gas, a heating element and a temperature detection element corresponding to the detection channel, a reference thermal path for generating a reference thermal response signal, a thermal excitation drive circuit, a status acquisition interface, a processor, a memory, and an industrial IoT communication interface. The thermal excitation drive circuit is connected to the heating element and outputs drive signals to the heating element according to the basic thermal excitation state and the detected thermal excitation state. The temperature detection element collects the detected thermal response signals under multiple thermal excitation states. The detected thermal response signal is the response signal formed by the temperature response amplitude, temperature change rate or compensation power change amount obtained by the temperature detection element under the basic thermal excitation state or the detected thermal excitation state with the sampling time. The reference thermal path outputs the reference thermal response signal. The status acquisition interface receives temperature, flow rate and pressure status signals of the detection channel. The memory stores the binary gas concentration calibration relationship and status correction rules. The processor generates thermal response feature values ​​based on the difference between the detected thermal response signal and the reference thermal response signal. After correcting the thermal response feature values ​​in combination with the status signal, it calls the binary gas concentration calibration relationship to generate the concentration result. When the difference between the detected thermal response signal and the reference thermal response signal meets the preset operating range, the processor binds the concentration result, sampling time, thermal excitation state, and operating state mark as a measurement record and outputs it through the industrial IoT communication interface. The industrial IoT communication interface also receives the reception verification information corresponding to the measurement record. The processor updates the output state and operating state mark of the measurement record according to the reception verification information so that the communication output result participates in the determination of the validity of the measurement record.

2. The lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 1, characterized in that, The process of the sensor forming a binary gas non-destructive testing channel and forming a reference thermal path includes: setting the detection channel as an inlet section, a heat exchange section and an outlet section connected in sequence, the inlet section, the heat exchange section and the outlet section together forming a binary gas non-destructive testing channel for the binary gas to pass through without damage, so that the binary gas enters the heat exchange section from the inlet section and is discharged through the outlet section. The heating element and the temperature detection element are set up in the corresponding heat exchange section so that the temperature detection element can obtain the detection thermal response signal under multiple thermal excitation states in the heat exchange section. The reference thermal path is set at a position adjacent to the heat exchange section but not in direct contact with the binary gas, so that the reference thermal path forms a reference thermal response signal corresponding to the detected thermal response signal during the same thermal excitation period when the heating element is driven by the driving signal. The status acquisition interface receives the temperature, flow rate or pressure status signals corresponding to the inlet section, heat exchange section or outlet section. The processor generates the correction basis for the thermal response feature value after corresponding the status signal with the sampling time of the detected thermal response signal.

3. The lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 2, characterized in that, The process of switching the thermal excitation state by the thermal excitation drive circuit includes: after the binary gas enters the heat exchange section, the thermal excitation drive circuit first outputs the drive signal of the basic thermal excitation state, and the temperature detection element collects the basic thermal response signal. When the variation amplitude of the basic thermal response signal within the preset sampling window meets the stability judgment range, the thermal excitation drive circuit switches to detect the thermal excitation state and outputs the corresponding drive signal. When the variation amplitude of the basic thermal response signal within the preset sampling window does not meet the stability judgment range, the processor delays the detection of the thermal excitation state switching and rereads the status signal received by the status acquisition interface until the variation amplitude of the basic thermal response signal within the new preset sampling window meets the stability judgment range. Then, the thermal excitation drive circuit switches to the detection of thermal excitation state and outputs the corresponding drive signal. The temperature detection element obtains the detection thermal response signal after the thermal excitation drive circuit completes the switch to the detection of thermal excitation state.

4. The lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 3, characterized in that, The process of the processor generating the thermal response feature value includes: extracting the settling time of the basic thermal response signal within the sampling window corresponding to the basic thermal excitation state; extracting the temperature change rate or compensation power change of the detected thermal response signal within the sampling window corresponding to the detected thermal excitation state; using the settling time of the basic thermal response signal as the sampling judgment basis; and using the temperature change rate or compensation power change of the detected thermal response signal as the concentration-sensitive quantity. When the sampling judgment criteria meet the preset sampling conditions, the processor extracts the maximum value, average value, integral value or linear fitting slope of the concentration-sensitive quantity within the sampling window corresponding to the detection thermal excitation state to obtain the concentration-sensitive numerical features. Then, the processor performs normalization, difference or proportional conversion processing on the concentration-sensitive numerical features according to the preset feature generation rules to generate the thermal response feature value. When the sampling criteria do not meet the preset sampling conditions, the processor stops using the detected thermal response signal within the current sampling window to generate the thermal response feature value.

5. A lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 1, characterized in that, The processor performs differential processing on the detected thermal response signal and the reference thermal response signal, including: obtaining the response amplitude of the detected thermal response signal under the detected thermal excitation state and the response amplitude of the reference thermal response signal in the same sampling period, and forming a thermal path difference according to the difference or ratio of response amplitude; When the thermal path difference falls within the preset operating range, the processor uses the thermal path difference as input to generate thermal response feature values. When the thermal path difference does not fall within the preset operating range, the processor generates an operating status flag corresponding to the current sampling period.

6. The lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 1, characterized in that, The process by which the processor corrects the thermal response characteristic value by combining the status signal includes: receiving the temperature, flow rate or pressure status signal of the detection channel by the status acquisition interface during the same sampling period when the temperature detection element acquires the thermal response signal, and establishing a correspondence between the status signal and the thermal response signal according to the sampling time; When the state signal is within the state range defined by the state correction rule, the processor generates a correction factor according to the state correction rule and uses the correction factor to correct the thermal response characteristic value. When the state signal exceeds the state range defined by the state correction rule, the processor stops using the thermal response feature value corresponding to the current sampling period to generate the concentration result and generates an operating state flag.

7. A lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 6, characterized in that, The process by which the processor calls the binary gas concentration calibration relationship to generate concentration results includes: determining the calibration relationship calling conditions based on the corrected thermal response characteristic value, and using the temperature, flow rate or pressure status signal of the detection channel as the verification basis for the calibration relationship calling conditions; When the calibration relationship call condition matches the gas type identifier and state range in the binary gas concentration calibration relationship, the processor calls the corresponding binary gas concentration calibration relationship and uses the corrected thermal response characteristic value as input to perform table lookup, interpolation or function calculation in the called binary gas concentration calibration relationship to obtain the corresponding concentration result. When the calibration relationship call conditions do not match the gas type identifier or status range in the binary gas concentration calibration relationship, the processor generates a running status flag corresponding to the calibration relationship call failure.

8. A lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 1, characterized in that, The process by which the processor binds the concentration result, sampling time, thermal excitation state, and operating state mark into a measurement record includes: taking the sampling time at which the temperature detection element obtains the detection thermal response signal as the sampling time, writing the concentration result into the concentration result field of the measurement record, writing the sampling time into the sampling time field of the measurement record, and establishing a correspondence between the concentration result and the sampling time; Write the basic thermal excitation state and the detected thermal excitation state into the thermal excitation state field, and write the judgment result of whether the difference between the detected thermal response signal and the reference thermal response signal meets the preset operating range into the operating state flag. When the concentration result, sampling time, thermal excitation state, and running status flag are all written to their corresponding values, the processor generates a measurement record. When any corresponding write is incomplete, the processor generates a measurement record with a missing record status.

9. A lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 8, characterized in that, The process of outputting the measurement record through the industrial IoT communication interface includes: the processor writes the measurement record into the upload queue according to the sampling time sequence, and verifies the correspondence between the concentration result, thermal excitation state and operating status marker in the measurement record before writing; When the correspondence of the measurement records meets the upload conditions, the industrial IoT communication interface outputs the measurement records to the industrial IoT node; When the correspondence of the measurement records does not meet the upload conditions, the processor retains the measurement records and generates a running status flag corresponding to the upload verification failure.

10. A lossless sensor for monitoring binary gas concentration based on the thermal principle according to claim 9, characterized in that, The process of the processor outputting the measurement record in the upload queue includes: after the industrial IoT communication interface outputs the measurement record to the industrial IoT node, the processor receives the reception verification information corresponding to the measurement record and maps the reception verification information to the sampling time; When the received verification information meets the consistency condition with the concentration result, thermal excitation state, and operating status flag in the measurement record, the processor marks the measurement record as output. If the received verification information is not returned within the preset verification time, or if the received verification information does not meet the consistency conditions with the concentration result, thermal excitation state, and operating status flag in the measurement record, the processor retains the measurement record in the upload queue and generates an operating status flag corresponding to the output verification failure.

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