A stay type boiler header expansion on-line monitoring device

Abstract

The application relates to the field of stay-type boiler monitoring, in particular to a stay-type boiler header expansion online monitoring device, which comprises a bottom plate, a bottom plate sensor installed on the bottom plate, and a shell installed on the bottom plate and covering the top of the bottom plate sensor; wherein a plurality of leveling holes are uniformly arranged around the center of the bottom plate, the plurality of leveling holes are circularly distributed, the bottom plate sensor is arranged at an angle of 90 degrees with the bottom plate, the bottom plate sensor is provided in multiple places, and the shell is internally provided with a space not interfering with the use of the plurality of bottom plate sensors. The application has the effect of discovering abnormal expansion problems of the measured components in time.

Description

Technical Field

[0001] This application relates to the field of wire-operated boiler monitoring, and in particular to an online monitoring device for the expansion of the header of a wire-operated boiler. Background Technology

[0002] Currently, in the power industry, thermal power units are routinely operating under peak-shaving and deep peak-shaving conditions to meet grid demands. This frequent load fluctuation causes boiler high-temperature pipes, headers, and other pressure-bearing components to continuously experience significant thermal expansion and contraction cycles. These repeated expansion and contraction fluctuations can induce fatigue damage or even cracking at stress concentration points, particularly at the fillet welds of header connection fittings. If such damage is not detected in time, it can easily lead to serious accidents such as leaks, and even unplanned unit shutdowns, posing a significant threat to the safe and stable operation of power plants.

[0003] For monitoring the expansion changes of high-temperature pipelines and headers, the industry currently relies heavily on traditional mechanical expansion indicators. These indicators typically employ a rigid pointer and a rigid dial for manual observation and recording. However, this method has significant drawbacks: the recording process is crude, relying on manual readings easily introduces subjective errors, and the overall measurement accuracy is extremely low. Furthermore, the manufacturing quality of these indicators varies considerably, and under prolonged exposure to harsh conditions such as high temperatures and vibrations, their mechanical structures are prone to jamming, deformation, or damage, often resulting in a state of failure. This prevents operators from accurately and in real-time grasping the actual expansion state and trends of the measured components, making it difficult to effectively identify potential structural risks. Utility Model Content

[0004] In order to detect abnormal expansion of the components under test in a timely manner, this application provides a wire-type online monitoring device for boiler header expansion.

[0005] This application provides a wire-operated boiler header expansion online monitoring device, which adopts the following technical solution:

[0006] A wire-operated boiler header expansion online monitoring device includes:

[0007] A base plate, wherein a plurality of leveling holes are evenly distributed around the center of the base plate in a circular pattern;

[0008] A base plate sensor is mounted on the base plate at a 90° angle to the base plate, and there are multiple base plate sensors.

[0009] The housing is mounted on the base plate and covers the multiple base plate sensors. The interior of the housing has space that does not interfere with the use of the multiple base plate sensors.

[0010] By adopting the above technical solution, the mounting base surface is calibrated with high precision through the evenly distributed leveling holes in the ring on the base plate, eliminating the tilt error of the measurement benchmark caused by uneven foundation and ensuring the reliability of subsequent sensor measurement data. The structure of multiple base plate sensors arranged orthogonally at 90° is used to construct a three-dimensional rectangular coordinate system measurement benchmark, avoiding the cumulative error of spherical coordinate system calculation. While the shell covers and protects multiple sets of sensors, the non-interference space reserved inside ensures that the pull wire can deflect freely throughout the entire expansion stroke of the boiler. This not only blocks the corrosion of precision sensors by dust and high-temperature steam on site, but also avoids measurement failure caused by mechanical collisions. It significantly improves the timeliness of early warning for abnormal operating conditions such as expansion obstruction and asymmetric deformation, and provides reliable data support for preventing fatigue cracking of the header fillet weld.

[0011] Preferably, the dimensions of the base plate are set according to the three-dimensional design expansion amount of the measuring point position on the base plate, the expansion range of the measuring point is within the range of the base plate, the length of the base plate is 400-415mm, and the width of the base plate is 350-370mm.

[0012] By adopting the above technical solution, the effective coverage area of ​​the base plate is precisely matched with the maximum motion envelope space of the three-dimensional expansion of the boiler header measuring point. This ensures that the guy wire can move freely within the opening of the base plate without any risk of jamming during the thermal expansion process. At the same time, the structural volume of the base plate can be minimized while reserving a safety boundary of ≥20mm, avoiding material waste and installation space conflicts caused by an excessively large base plate. It also completely avoids the failure mode of the guy wire being sheared and broken by the edge of the opening when it deflects due to an excessively small base plate. Even if the base plate can be directly connected and fixed to the adjacent steel beam, it can improve the vibration and deformation resistance and ensure the long-term stability of the expansion monitoring data under the deep peak shaving conditions of the unit.

[0013] Preferably, the base plate is made of carbon steel, the base plate is 4mm thick, and the surface of the base plate is provided with an anti-corrosion structural layer.

[0014] By adopting the above technical solution, a 4mm thick base plate is manufactured using carbon steel substrate, which achieves lightweighting while ensuring structural rigidity. Furthermore, the thermal expansion coefficient of carbon steel matches that of the boiler steel frame, avoiding measurement benchmark drift caused by warping and deformation of the base plate due to thermal expansion differences. The anti-corrosion structural layer set on the surface of the base plate forms a double protective barrier, preventing rust and corrosion of the plate caused by rain leakage in the boiler room, thus extending the service life of the base plate.

[0015] Preferably, there are 12 leveling holes, the diameter of the leveling holes is 6mm, and the bottom plate leveling bolts are inserted into the leveling holes.

[0016] By adopting the above technical solution, 12 leveling holes with a diameter of 6mm and leveling bolts are used to form a high-density circumferentially distributed fine-tuning structure, which allows the flatness of the base plate to be adjusted in any direction, eliminating the tilt of the measurement reference caused by the welding deformation of the boiler steel frame; the leveling holes and leveling bolts form a dynamic gap of 0.05-0.2mm, which not only ensures that the bolts can be freely inserted to achieve rapid coarse adjustment, but also eliminates the gap by self-centering of the bolt conical surface after locking.

[0017] Preferably, a mounting hole is provided on the base plate near the edge of the base plate, and the housing is mounted to the base plate through the mounting hole.

[0018] By adopting the above technical solution, an edge-distributed load-bearing structure is formed by opening mounting holes on the edge of the base plate and fixing the shell.

[0019] Preferably, three mounting holes with a diameter of 8mm are provided near the edge of each of the base plates.

[0020] By adopting the above technical solution, the installation between the outer shell and the base plate is made more stable.

[0021] Preferably, the base plate sensor is a wire-type displacement sensor, and there are three base plate sensors, each corresponding to multiple axial expansion directions of the monitoring point.

[0022] By adopting the above technical solution, and by setting up three wire-type displacement sensors corresponding to the axial expansion direction of the monitoring points respectively, the three-dimensional expansion amount is directly output as the sensor reading component, eliminating the cumulative error of spherical coordinate conversion caused by inclinometer drift in the single sensor solution; the physical orthogonal layout of the three sensors forms spatial measurement redundancy, and when any sensor fails due to dust jamming, the remaining dual-axis data can still reconstruct most of the expansion trajectory, and combined with the axial orientation constraint mechanism, the wire is forced to move within the preset axial expansion path, avoiding vector decomposition error caused by oblique traction.

[0023] Preferably, the overall dimensions of the housing are set in conjunction with the three-dimensional design expansion amount of the measuring point location, and the expansion range of the measuring point is located within the housing area.

[0024] By adopting the above technical solution, the overall size of the housing is strictly matched with the three-dimensional design expansion amount of the measuring point position, so that a dynamic protection space that completely encloses the expansion movement trajectory is formed inside the housing, eliminating measurement failures caused by wire jamming or universal joint over-limit deflection due to housing interference.

[0025] Preferably, the end of the housing away from the base plate sensor is provided with a sealing rubber sheet.

[0026] By adopting the above technical solution, a sealing rubber is set at the end of the housing away from the bottom plate sensor to form a dynamic elastic sealing barrier. The rubber fits and compensates for displacement in real time during the extension and retraction of the wire, eliminating the problem of dust leakage caused by the gap due to the thermal expansion difference of the traditional rigid sealing cover.

[0027] Preferably, a plurality of heat dissipation holes are uniformly formed on the side wall of the housing.

[0028] By adopting the above technical solution, multiple heat dissipation holes are evenly opened on the side wall of the housing to avoid zero-point drift of electronic components due to high-temperature deterioration.

[0029] In summary, this application includes at least one of the following beneficial technical effects:

[0030] 1. The mounting base is leveled with a ring of evenly distributed leveling holes on the base plate to achieve high-precision horizontal calibration, eliminating the tilt error of the measurement benchmark caused by uneven foundation and ensuring the reliability of subsequent sensor measurement data; multiple base plate sensors are arranged orthogonally at 90° to construct a three-dimensional rectangular coordinate system measurement benchmark, avoiding the cumulative error of spherical coordinate system calculation; while the shell covers and protects multiple sets of sensors, the non-interference space reserved inside ensures that the pull wire can deflect freely throughout the entire expansion stroke of the boiler, which not only blocks the corrosion of precision sensors by on-site dust and high-temperature steam, but also avoids measurement failure caused by mechanical collision.

[0031] 2. A 4mm thick base plate is made of carbon steel substrate, which achieves lightweight while ensuring structural rigidity. The thermal expansion coefficient of carbon steel matches that of the boiler steel frame, avoiding measurement benchmark drift caused by warping and deformation of the base plate due to thermal expansion differences. The anti-corrosion structural layer set on the surface of the base plate forms a double protective barrier to prevent rust and corrosion of the plate caused by rain leakage in the boiler room, thus extending the service life of the base plate.

[0032] 3. By setting up three wire-type displacement sensors corresponding to the axial expansion direction of the monitoring points, the three-dimensional expansion amount is directly output as sensor reading components, eliminating the cumulative error of spherical coordinate conversion caused by inclinometer drift in the single-sensor scheme; the physical orthogonal layout of the three sensors forms spatial measurement redundancy. When any sensor fails due to dust jamming, the remaining dual-axis data can still reconstruct most of the expansion trajectory. Combined with the axial orientation constraint mechanism, the wire is forced to move within the preset axial expansion path, avoiding vector decomposition errors caused by oblique traction. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall structure of the online monitoring device for expansion of the boiler header in the embodiments of this application;

[0034] Figure 2 This is a schematic diagram showing the arrangement of the sensors on the base plate;

[0035] Figure 3 This is a schematic diagram illustrating the base plate structure.

[0036] Explanation of reference numerals in the attached drawings: 1. Base plate; 11. Leveling hole; 12. Mounting hole; 2. Base plate sensor; 3. Housing; 31. Space; 32. Sealing rubber; 33. Heat dissipation hole. Detailed Implementation

[0037] The following is in conjunction with the appendix Figure 1-3 This application will be described in further detail.

[0038] This application discloses an online monitoring device for the expansion of a pull-wire boiler header. The online monitoring device for the expansion of a pull-wire boiler header includes a base plate 1, a base plate sensor 2 mounted on the base plate 1, and a housing 3 mounted on the base plate 1 and covering the base plate sensor 2.

[0039] The base plate 1 is a square base plate with multiple leveling holes 11 evenly distributed around its center in a circular pattern. These circular leveling holes 11 enable high-precision horizontal calibration of the mounting surface, eliminating measurement reference tilt errors caused by uneven foundations and ensuring the reliability of subsequent sensor measurement data. There are 12 leveling holes 11, each 6mm in diameter, through which leveling bolts are inserted. These 12 leveling holes 11, along with the leveling bolts, form a high-density, evenly distributed circular fine-tuning structure, allowing the flatness of the base plate 1 to be adjusted gradients in any direction, eliminating measurement reference tilt caused by welding deformation of the boiler steel frame. A dynamic gap of 0.05-0.2mm is formed between the leveling holes 11 and the leveling bolts, ensuring both free bolt insertion for rapid coarse adjustment and self-centering of the bolt's conical surface after tightening to eliminate the gap.

[0040] In an optional embodiment, the dimensions of the base plate 1 are set according to the three-dimensional design expansion amount of the measuring point position on the base plate 1. The expansion range of the measuring point is within the range of the base plate 1. The length of the base plate 1 is 400-415mm, and the width of the base plate 1 is 350-370mm. This ensures that the effective coverage area of ​​the base plate 1 accurately matches the maximum motion envelope space 31 of the three-dimensional expansion amount of the measuring point in the boiler header. This ensures that the pull wire can move freely within the opening of the base plate 1 without any risk of jamming during the thermal expansion process. At the same time, the structural volume of the base plate 1 can be minimized while reserving a safety boundary of ≥20mm, avoiding material waste and installation space conflicts caused by an excessively large base plate 1. It also completely avoids the failure mode of shearing and breaking of the pull wire at the edge of the opening when the base plate 1 is too small. Even if the base plate 1 can be directly connected and fixed to the adjacent steel beam, improving the vibration deformation resistance, it can also ensure the long-term stability of the expansion monitoring data under the deep peak shaving conditions of the unit.

[0041] In a preferred embodiment, the base plate 1 is made of carbon steel and has a thickness of 4mm. The surface of the base plate 1 is provided with an anti-corrosion structural layer. Optionally, the anti-corrosion structural layer is an anti-corrosion paint applied to the surface of the base plate 1. Manufacturing the 4mm thick base plate 1 using carbon steel as the base material ensures structural rigidity while achieving lightweight design. Furthermore, the coefficient of thermal expansion of carbon steel matches that of the boiler steel frame, preventing measurement reference drift caused by warping and deformation of the base plate 1 due to differences in thermal expansion. The anti-corrosion structural layer on the surface of the base plate 1 forms a double protective barrier, preventing rust and corrosion of the plate due to leaks in the boiler room, thus extending the service life of the base plate 1.

[0042] The base plate sensor 2 is arranged at a 90° angle to the base plate 1, and multiple base plate sensors 2 are installed. This structure, with multiple sets of base plate sensors 2 arranged orthogonally at 90°, establishes a three-dimensional rectangular coordinate system measurement benchmark, avoiding accumulated errors in spherical coordinate system calculations. In an optional embodiment, the base plate sensor 2 is a wire-type displacement sensor, with three locations, each corresponding to multiple axial expansion directions of the monitoring point. By setting three wire-type displacement sensors corresponding to the axial expansion directions of the monitoring points, the three-dimensional expansion amount is directly output as sensor reading components, eliminating the accumulated errors in spherical coordinate conversion caused by inclinometer drift in the single-sensor scheme. The physically orthogonal layout of the three sensors forms spatial measurement redundancy 31. When any sensor fails due to dust jamming, the remaining dual-axis data can still reconstruct most of the expansion trajectory. Combined with an axial orientation constraint mechanism, the wire is forced to move within a preset axial expansion path, avoiding vector decomposition errors caused by oblique traction.

[0043] The housing 3 is mounted on the base plate 1 and covers multiple base plate sensors 2. The housing 3 has an internal space 31 that does not interfere with the use of the multiple base plate sensors 2. While covering and protecting multiple sets of sensors, the non-interference space 31 inside the housing 3 ensures that the pull wire can deflect freely throughout the entire expansion stroke of the boiler, thus preventing the corrosion of precision sensors by dust and high-temperature steam and avoiding measurement failures caused by mechanical collisions. In an optional embodiment, the overall dimensions of the housing 3 are set in conjunction with the three-dimensional design expansion amount of the measuring point location, and the expansion range of the measuring point is within the housing 3. By strictly matching the overall dimensions of the housing 3 to the three-dimensional design expansion amount of the measuring point location, a dynamic protective space 31 that completely encloses the expansion trajectory is formed inside the housing 3, eliminating measurement failures caused by pull wire jamming or universal joint over-limit deflection due to interference from the housing 3.

[0044] In a preferred embodiment, a sealing rubber 32 is provided at the end of the housing 3 furthest from the base plate sensor 2. This sealing rubber 32 forms a dynamic elastic sealing barrier. The rubber 32 compensates for displacement during the extension and contraction of the cable, eliminating the gap and dust leakage problem caused by thermal expansion differences in traditional rigid sealing covers. This ensures both the sealing of the housing 3 and ease of equipment maintenance. Multiple heat dissipation holes 33 are evenly distributed on the sidewall of the housing 3 to prevent zero-point drift of electronic components due to high-temperature degradation. In an optional embodiment, six heat dissipation holes 33 are evenly distributed; preferably, the diameter of the heat dissipation holes 33 is 4mm. In a preferred embodiment, an anti-corrosion structural layer is provided on the exterior of the housing 3. Optionally, the anti-corrosion structural layer is an anti-corrosion paint applied to the surface of the base plate 1. The dead corners of the housing 3 are chamfered to prevent scratches to maintenance personnel during handling.

[0045] The implementation principle of this application embodiment is as follows: the mounting base surface is calibrated with high precision through the leveling holes 11 evenly distributed in a ring on the base plate 1, eliminating the tilt error of the measurement reference caused by uneven foundation, and ensuring the reliability of subsequent sensor measurement data; a structure in which multiple sets of base plate sensors 2 are arranged orthogonally at 90° is adopted to construct a three-dimensional rectangular coordinate system measurement reference, avoiding the accumulation error of spherical coordinate system calculation; while the housing 3 covers and protects multiple sets of sensors, the non-interference space 31 reserved inside it ensures that the pull wire can deflect freely during the entire expansion stroke of the boiler, which not only blocks the corrosion of precision sensors by on-site dust and high-temperature steam, but also avoids measurement failure caused by mechanical collision.

[0046] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0047] The preferred embodiments of this utility model disclosed above are merely illustrative of the present utility model. These preferred embodiments do not exhaustively describe all details, nor do they limit the utility model to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of this utility model, thereby enabling those skilled in the art to better understand and utilize it. This utility model is limited only by the claims and their full scope and equivalents.

Claims

1. A wire-operated boiler header expansion online monitoring device, characterized in that, include: The base plate (1) has a plurality of leveling holes (11) evenly distributed around the center of the base plate (1), and the plurality of leveling holes (11) are distributed in a circular pattern; The base plate sensor (2) is installed on the base plate (1) and arranged at 90° with the base plate (1). There are multiple base plate sensors (2). The housing (3) is mounted on the base plate (1) and covers the multiple base plate sensors (2). The housing (3) has a space (31) inside that does not interfere with the use of the multiple base plate sensors (2).

2. The online monitoring device for boiler header expansion according to claim 1, characterized in that, The dimensions of the base plate (1) are set according to the three-dimensional design expansion amount of the measuring point position on the base plate (1). The expansion range of the measuring point is within the range of the base plate (1). The length of the base plate (1) is 400-415mm and the width of the base plate (1) is 350-370mm.

3. The online monitoring device for boiler header expansion according to claim 2, characterized in that, The base plate (1) is made of carbon steel and has a thickness of 4 mm. The surface of the base plate (1) is provided with an anti-corrosion structural layer.

4. The online monitoring device for boiler header expansion according to claim 1, characterized in that, There are 12 leveling holes (11), the diameter of the leveling holes (11) is 6mm, and the leveling bolts of the base plate (1) are inserted into the leveling holes (11).

5. The online monitoring device for boiler header expansion according to claim 1, characterized in that, The base plate (1) has a mounting hole (12) near its edge, and the housing (3) is mounted to the base plate (1) through the mounting hole (12).

6. The online monitoring device for boiler header expansion according to claim 5, characterized in that, Three mounting holes (12) are provided near the edge of each of the base plates (1), and the diameter of the mounting holes (12) is 8 mm.

7. The online monitoring device for boiler header expansion according to claim 1, characterized in that, The base plate sensor (2) is a pull-wire displacement sensor. There are three base plate sensors (2), and the three base plate sensors (2) correspond to multiple axial expansion directions of the monitoring point.

8. The online monitoring device for expansion of a pull-wire boiler header according to claim 2, characterized in that, The overall dimensions of the housing (3) are set in conjunction with the three-dimensional design expansion amount of the measuring point position, and the expansion range of the measuring point is within the range of the housing (3).

9. The online monitoring device for boiler header expansion according to claim 8, characterized in that, The housing (3) has a sealing rubber sheet (32) at the end away from the base plate sensor (2).

10. The online monitoring device for boiler header expansion according to claim 8, characterized in that, Multiple heat dissipation holes (33) are evenly provided on the side wall of the housing (3).

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