An on-line detection method for air leakage of a pulse valve diaphragm of a dust collector
By using an infrared thermometer to detect temperature differences in the blowpipe while the dust collector is running, the high cost and high intensity of pulse valve diaphragm leakage detection in existing technologies have been solved, enabling rapid and accurate online detection and reducing operation and maintenance costs and production impact.
Patent Information
- Application Number
- CN202611429717.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-09-15
- Publication Date
- 2026-11-03
AI Technical Summary
Existing technologies cannot quickly and accurately detect pulse valve diaphragm leaks while the dust collector is running, and traditional detection methods require shutdown and disassembly, which are costly and labor-intensive.
An industrial infrared thermometer is used to periodically check the temperature difference between the outer wall of the blowpipe and the ambient temperature under normal operating conditions of the dust collector. The temperature difference is used to determine whether there is air leakage in the diaphragm. The specific judgment rules are: |T1-T0|≤1.5℃ indicates no air leakage, 1.5℃<|T1-T0|<3℃ indicates wear and aging, and |T1-T0|≥3℃ indicates damage and air leakage. A flat location on the outer wall of the blowpipe is selected to avoid interference. The detection distance and emissivity are set to 10-15cm and 0.95, respectively, and the ambient temperature is detected simultaneously.
It enables rapid and accurate detection of pulse valve diaphragm leaks without shutting down the machine or disassembling it, reducing maintenance costs and labor intensity, improving detection accuracy, and is applicable to various dusty working conditions, thus reducing production downtime losses and equipment wear.
Abstract
Description
Technical Field
[0001] This invention relates to the field of fault detection technology for bag / cartridge dust collectors, and specifically to an online detection method for air leakage in the diaphragm of a dust collector pulse valve. Background Technology
[0002] Bag / cartridge dust collectors rely on electromagnetic pulse valves to periodically blow compressed air to clean dust adhering to the filter bags. Right-angle and submerged pulse valves are the mainstream valve types in the industry. The rubber diaphragm is the core sealing and opening / closing component of the pulse valve. It is subjected to high-pressure airflow impact, dust corrosion, and repeated opening and closing compression for a long time, which can easily lead to cracking, perforation, edge delamination, seal failure, and spring damage. This can cause problems such as pulse valve leakage, excessive air pressure loss in the air tank, dust removal pulse failure, filter bag clogging, and overload power consumption of the air compressor.
[0003] The current industry-standard diaphragm leak detection methods have four major drawbacks: (1) The machine must be shut down and the gas supply stopped, interrupting the production operation of the dust removal system and affecting the environmental protection compliance of the workshop. (2) The disassembly and assembly of valve bodies is a large workload. Dozens of pulse valves in a single dust collector need to be disassembled one by one, and the operation and maintenance takes a very long time. (3) The disassembly and assembly process is prone to damage to the valve body threads and sealing gaskets, increasing the cost of spare parts; (4) Minor hidden diaphragm cracks are difficult to detect visually, and the accuracy of disassembly and inspection is low, making it easy to miss detection.
[0004] Current leak detection methods for pulse valves only include auditory leak detection, vibration detection, and electrical control signal detection. Auditory leak detection is greatly affected by noise from factory fans and equipment, and cannot detect leaks at small flow rates. Vibration detection requires the installation of sensors, which is costly and easily damaged in dusty environments. Electrical control detection can only determine solenoid valve energization failures and cannot determine leaks due to physical damage to the diaphragm. Currently, there is no mature detection method in the industry that can quickly and cost-effectively determine diaphragm leaks without requiring shutdown or disassembly. Summary of the Invention
[0005] The present invention aims to provide an online detection method for air leakage of pulse valve diaphragm in dust collectors. This method can achieve online detection of air leakage of pulse valve diaphragm while improving the operating rate of dust collectors.
[0006] The online detection method for air leakage of the diaphragm of the dust collector pulse valve is characterized by comprising the following steps: S1. Keep the dust collector running normally, the air tank maintains pressure and supplies air normally, and the pulse controller is in normal standby mode; select the outer wall of the vertical outlet blowpipe at the lower end of each group of pulse valves as a fixed temperature measurement point. S2. Periodically check the temperature T1 at the fixed temperature measurement point and the ambient temperature T0, and calculate the temperature difference between the two to determine whether there is air leakage in the pulse valve diaphragm. The specific judgment rules are as follows: When |T1-T0|≤1.5℃, the diaphragm is properly sealed and leak-free; When 1.5℃ < |T1-T0| < 3℃, the diaphragm wears and ages, the spring is damaged, and there is a risk of air leakage. When |T1-T0|≥3℃, the diaphragm is damaged and cracked, and the spring is damaged, resulting in continuous air leakage.
[0007] The selection principle for the fixed temperature measurement point is to choose a flat pipe wall position on the outer wall of the blow pipe, avoiding weld joints, insulation layers, and dust agglomeration locations; before testing, wipe away the floating dust at the temperature measurement point to avoid dust insulation interfering with the temperature measurement value.
[0008] The principle for selecting the fixed temperature measurement point is to choose a position on the outer wall of the blowpipe that is 5-8cm below the pulse valve body.
[0009] The temperature detection at the fixed temperature measurement point and the ambient temperature includes the following steps: An industrial infrared thermometer is used to detect the temperature at a fixed temperature measurement point. The temperature measurement distance is controlled at 10-15cm, the temperature emissivity is set to 0.95, and the single-point temperature measurement time is 1-2s. The real-time temperature T1 of the pipe wall is obtained. An industrial infrared thermometer with the same emissivity and measurement duration is used to simultaneously detect the temperature T0 of the dust collector housing and the surrounding ambient air.
[0010] Preferably, the following steps are also included: In step S2: For pulse valves where 1.5℃ < |T1-T0| < 3℃ are detected, mark them, increase the monitoring and temperature measurement frequency, and disassemble and replace them when the temperature difference approaches the upper limit of 3℃. For pulse valves where |T1-T0|≥3℃ are detected, disassemble and replace them immediately.
[0011] The pulse valve is either a DMF-Z right-angle pulse valve or a DMF-Y submerged pulse valve.
[0012] The normal pressure range for the gas storage tank to maintain and supply gas is 0.3MPa-0.7MPa.
[0013] When detecting temperature, the equipment maintains normal production conditions without needing to stop, depressurize, or disconnect power.
[0014] Preferably, in step S2, during winter, each temperature threshold in the judgment rule is increased by 0.5℃.
[0015] The beneficial effects of this invention are as follows: The detection method of this invention does not require shutdown or air supply interruption: the dust collector and air tank operate normally throughout the process, without interrupting production or affecting dust removal and environmental protection operations, and without any production downtime losses.
[0016] The method of the present invention does not require disassembling the valve body, will not damage the valve body threads, diaphragm, or sealing gasket, and has no loss of disassembly and assembly parts.
[0017] The method of this invention can detect the temperature of a single pulse valve in just 3-5 seconds. Dozens of pulse valves on a dust collector can be checked in just a few minutes. Even minor hidden cracks and leaks can be detected by temperature difference, with an accuracy of over 99%.
[0018] The method of this invention uses only a conventional industrial infrared thermometer, without the need to install sensors, wiring, or modify the electrical control system. It has zero modification cost, can be operated by maintenance personnel with no prior experience, and is low in cost and high in efficiency.
[0019] The method of this invention is highly versatile: it is compatible with right-angle and submerged pulse valves of all specifications, and is suitable for all dust removal conditions in cement plants, chemical plants, power plants, and sand and gravel plants, and has good application prospects. Detailed Implementation
[0020] The present invention will now be described in detail with reference to specific embodiments.
[0021] Example 1 The online detection method for air leakage of the diaphragm of the dust collector pulse valve in this embodiment includes the following steps: The online detection method for air leakage of the diaphragm of the dust collector pulse valve is characterized by comprising the following steps: S1. Keep the dust collector running normally, the air tank maintains pressure and supplies air normally, and the pulse controller is in normal standby mode; select the outer wall of the vertical outlet blowpipe at the lower end of each group of pulse valves as a fixed temperature measurement point. The principle for selecting the fixed temperature measurement point is to choose a position on the outer wall of the blowpipe 6cm below the pulse valve body.
[0022] The selection principle for the fixed temperature measurement point is to choose a flat pipe wall position on the outer wall of the blow pipe, avoiding weld joints, insulation layers, and dust agglomeration locations; before testing, wipe away the floating dust at the temperature measurement point to avoid dust insulation interfering with the temperature measurement value.
[0023] S2. Periodically check the temperature T1 at the fixed temperature measurement point and the ambient temperature T0, and calculate the temperature difference between the two to determine whether there is air leakage in the pulse valve diaphragm. The specific judgment rules are as follows: When |T1-T0|≤1.5℃, the diaphragm is properly sealed and leak-free; When 1.5℃ < |T1-T0| < 3℃, the diaphragm is worn and aged, posing a risk of leakage; mark it, increase the frequency of temperature monitoring, and disassemble and replace it when the temperature difference approaches the upper limit of 3℃; If |T1-T0|≥3℃, and the diaphragm is damaged, cracked, or leaking continuously, it should be disassembled and replaced immediately. The temperature detection at the fixed temperature measurement point and the ambient temperature includes the following steps: An industrial infrared thermometer was used to detect the temperature at a fixed measurement point. The measurement distance was controlled at 12cm, the emissivity was set to 0.95, and the single-point measurement time was 2s. The real-time temperature T1 of the pipe wall was obtained. An industrial infrared thermometer with the same emissivity and measurement duration is used to simultaneously detect the ambient air temperature T0 around the dust collector.
[0024] The pulse valve is either a DMF-Z right-angle pulse valve or a DMF-Y submerged pulse valve.
[0025] The normal pressure range for the gas storage tank to maintain and supply gas is 0.3MPa-0.7MPa.
[0026] When monitoring temperature, the equipment maintains normal production conditions, requiring no shutdown, no pressure relief, and no power outage.
[0027] In step S2, during winter, the temperature thresholds in the judgment rules are increased by 0.5℃ respectively.
[0028] Example 2 Taking a branch factory in Pingguo, Guangxi Zhuang Autonomous Region as an example, a single dust collector equipped with 30 pulse valves is used as the calculation object. The economic benefits are calculated from multiple dimensions, including labor hours, compressed air energy consumption, on-site cleaning time, damage from accidentally disassembled spare parts, and avoiding downtime losses.
[0029] 1. Cost savings in manual maintenance time Basic requirements: Labor cost is 200 yuan / person / day, which is 25 yuan / person / hour. Maintenance work requires 2 people to work together.
[0030] Traditional maintenance method: Without using patented methods, troubleshooting a single pulse valve takes 25 minutes. The theoretical working time for troubleshooting all 30 pulse valves is 30 * 25 = 750 minutes (12.5 hours). Moreover, it requires repeated air supply and shut-off, and there is also the possibility of misjudgment and repeated disassembly and assembly, which takes even longer in practice. It requires 2 workers, resulting in high labor costs. At the same time, it involves the ineffective disassembly and assembly of a large number of intact valve bodies, resulting in wasted labor.
[0031] Using this patented technology: determining the fault of a single pulse valve takes only 5-10 seconds, and checking the temperature of all 30 pulse valves takes only a few minutes; only the faulty valves that have been accurately marked are disassembled and repaired, and the replacement and repair of a single valve is controlled within 10 minutes. If all 30 valves are replaced, it would take 5 hours, saving 7.5 hours of time and reducing labor by 7.5 * 25 = 187.5.
[0032] Taking the example of multiple pulse valves leaking in a single dust collector, assuming there are 3 faulty valves: Traditional method: All 30 pulse valves need to be disassembled and inspected one by one, which takes a total of 750 minutes and requires 2 people to work. The labor cost is 750 / 60*25*2=625 yuan.
[0033] Patented method: Temperature measurement and troubleshooting takes a few minutes, only 3 faulty valves are repaired, repair time is 3×10=30 minutes; 2 people work together, labor cost: 30 / 60*25*2=25 yuan.
[0034] The labor cost for a single fault repair can be reduced by approximately 600 yuan. The more faulty pulse valves there are, the more significant the savings will be.
[0035] 2. Reduced compressed air energy consumption and loss Parameters: A single leaking pulse valve leaks 4.96 Nm³ of compressed air per hour, with a leakage cost of 1.49 yuan / hour (calculated based on a compressed air cost of 0.3 yuan / Nm³).
[0036] A damaged pulse valve diaphragm will cause continuous compressed air leakage. Traditional detection methods cannot pinpoint the fault location online, and the leak often occurs during prolonged operation. If three pulse valves are continuously leaking: Economic loss per hour: 3 × 1.49 = 4.47 yuan; calculated based on the equipment running for 24 hours a day, daily leakage loss: 4.47 × 24 = 107.28 yuan.
[0037] 3. Saves labor costs for on-site dust cleaning A leaking diaphragm in the pulse valve of a dust collector can cause the system's dust removal to fail, leading to dust and ash leakage from the equipment.
[0038] - Under normal operating conditions: It takes 15 minutes for one person to clean the environment; - After a pulse valve malfunction causes dust leakage: 1 person is needed to clean it. 2.5 hours.
[0039] Based on a daily wage of 200 yuan, the normal cleaning cost is 15 / 60*25=6.25 yuan; the cleaning cost after a breakdown is calculated as the midpoint of 2.25 hours, which is 2.25*25=56.25 yuan.
[0040] A single malfunction results in an additional cleaning labor cost of 50 yuan.
[0041] II. Social Benefits 1. Improve the reliability of environmental protection equipment operation and ensure that environmental protection emissions meet standards. This detection method can quickly identify the diaphragm damage and critical wear state of the pulse valve without interrupting the operation of the dust collector, enabling fault handling and preventive maintenance. It avoids dust removal failure, dust collection pipe blockage, large amount of dust accumulation in the ash hopper, large amount of dust accumulation collapse, and dust overflow on site caused by pulse valve leakage, thereby reducing the risk of fugitive dust emissions, ensuring environmentally compliant production in the plant area, and reducing dust pollution and material loss.
[0042] 2. Reduce the workload of maintenance personnel and improve their working conditions. Traditional maintenance requires climbing to repeatedly disassemble and reassemble dozens of pulse valves, which is labor-intensive and time-consuming. The patented method relies on non-contact temperature measurement with an infrared thermometer, and only repairs the faulty valve body, which greatly reduces the amount of disassembly and reassembly work, reduces the time that maintenance personnel spend working at height, reduces personnel fatigue, and improves on-site operation safety.
[0043] 3. Low testing threshold, facilitating industry promotion and popularization. Using only a general-purpose industrial infrared thermometer, no new sensors or modifications to the electrical control system are required; maintenance personnel can be trained quickly and easily. It is also compatible with right-angle DMF (Digital Microfiber) thermometers. Z and DMF-Y series of submerged pulse valves are suitable for various dust conditions in cement plants, chemical plants, power plants, sand and gravel plants, etc., providing standardized practical methods for the operation and maintenance of bag and cartridge dust collectors, and promoting the upgrading of dust collection equipment operation and maintenance technology.
[0044] 4. Contribute to industrial energy conservation and carbon reduction Timely detection and elimination of pulse valve leaks reduces ineffective compressed air consumption, lowers the operating load of air compressors, reduces power consumption, and indirectly reduces factory carbon emissions, aligning with the development direction of energy conservation and emission reduction in the industrial sector.
[0045] 5. Enables fault prediction and early warning. By identifying the critical wear and aging state of the diaphragm within a temperature difference range, it is possible to prepare inventory in advance for preventative replacement, avoid sudden air leakage failures of the pulse valve, reduce the probability of unplanned equipment failures, and improve the overall operational stability of the dust removal system.
[0046] 6. Savings in indirect material costs and downtime 1) Avoid damage during valve body disassembly and assembly: Traditional maintenance involves disassembling a large number of intact pulse valves, which can easily damage the valve body threads and gaskets, resulting in additional scrap of seals and valve bodies. Patented technology only disassembles and assembles the valve body after confirming the fault, reducing the cost of spare parts.
[0047] 2) Avoid production downtime losses: Traditional testing requires the dust collector to be shut down and depressurized, interrupting production and resulting in production stoppages and reduced output; this patented technology allows for continuous online testing without interrupting production, thus avoiding production losses caused by downtime.
[0048] 3) Filter media life protection: Continuous air leakage from the pulse valve will cause a drop in air tank pressure and failure of pulse cleaning, leading to filter bag / filter cartridge clogging and accelerated filter media scrapping; quickly eliminate air leakage faults, extend the service life of filter bags and filter cartridges, and reduce filter media purchase and replacement costs.
[0049] In summary, by applying this patent, multiple savings can be achieved in terms of manual maintenance, compressed air energy consumption, on-site cleaning, spare parts wear and tear, and downtime losses in the event of a single dust collector pulse valve failure. The cumulative economic benefits over the equipment's operating cycle are considerable.
[0050] The above-disclosed content is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Therefore, all equivalent technical changes made based on the content of this specification are included within the scope of protection of the present invention. Furthermore, the elements therein can be updated as technology develops. The above units are merely examples, and those skilled in the art can adopt corresponding units according to actual needs when implementing this solution.
Claims
1. A method for online detection of air leakage in the diaphragm of a dust collector pulse valve, characterized in that, Includes the following steps: S1. Keep the dust collector running normally, the air tank maintains pressure and supplies air normally, and the pulse controller is in normal standby mode; select the outer wall of the vertical outlet blowpipe at the lower end of each group of pulse valves as a fixed temperature measurement point. S2. Periodically check the temperature T1 at the fixed temperature measurement point and the ambient temperature T0, and calculate the temperature difference between the two to determine whether there is air leakage in the pulse valve diaphragm. The specific judgment rules are as follows: When |T1-T0|≤1.5℃, the diaphragm is properly sealed and leak-free; When 1.5℃ < |T1-T0| < 3℃, the diaphragm wears and ages, posing a risk of leakage. When |T1-T0|≥3℃, the diaphragm breaks and cracks, resulting in continuous air leakage.
2. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that: The selection principle for the fixed temperature measurement point is to choose a flat pipe wall position on the outer wall of the blow pipe, avoiding weld joints, insulation layers, and dust agglomeration locations; before testing, wipe away the floating dust at the temperature measurement point to avoid dust insulation interfering with the temperature measurement value.
3. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that: The principle for selecting the fixed temperature measurement point is to choose a position on the outer wall of the blowpipe that is 5-8 cm below the pulse valve body.
4. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that: The temperature detection at the fixed temperature measurement point and the ambient temperature includes the following steps: An industrial infrared thermometer is used to detect the temperature at a fixed temperature measurement point. The temperature measurement distance is controlled at 10-15cm, the temperature emissivity is set to 0.95, and the single-point temperature measurement time is 1-2s. The real-time temperature T1 of the pipe wall is obtained. Industrial infrared thermometers with the same emissivity and measurement duration are used to simultaneously detect the temperature T0 of the dust collector housing or the surrounding ambient air.
5. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that, It also includes the following steps: In step S2: For pulse valves that are detected to have a temperature difference of 1.5℃ < |T1-T0| < 3℃, mark them as key items for subsequent inspection, increase the monitoring and temperature measurement frequency, and disassemble and replace them when the temperature difference approaches the upper limit of 3℃. For pulse valves where |T1-T0|≥3℃ are detected, disassemble and replace them immediately.
6. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that: The pulse valve is either a DMF-Z right-angle pulse valve or a DMF-Y submerged pulse valve.
7. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that: The normal pressure range for the gas storage tank to maintain and supply gas is 0.3MPa-0.7MPa.
8. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that: When monitoring temperature, the equipment maintains normal production conditions, requiring no shutdown, no pressure relief, and no power outage.
9. The online detection method for air leakage of the diaphragm of the dust collector pulse valve as described in claim 1, characterized in that, It also includes the following steps: In step S2, during winter, the temperature thresholds in the judgment rules are increased by 0.5℃ respectively.