An electrode boiler electrode loss rate on-line monitoring device capable of automatic calibration

Abstract

The utility model provides an electrode boiler electrode loss rate on -line monitoring device of automatic calibration, including first clamping unit and second clamping unit for clamping upper end and lower end, first clamping unit and second clamping unit all include two opposite clamping pieces, the inside of clamping piece is equipped with the arc clamping surface of adapting with electrode outer wall, be equipped with conducting contact piece on the arc clamping surface, the conducting contact piece in first clamping unit and second clamping unit is connected with resistance detection module through wire, and resistance detection module is used to apply detection current to electrode through the conducting contact piece and gathers voltage signal, and resistance detection module is connected with corrosion evaluation module through controller. The utility model can effectively solve the low technical problem of offline detection efficiency in the existing electrode boiler electrode loss monitoring.

Description

Technical Field

[0001] This utility model relates to the field of electrode boiler monitoring technology, specifically to an online monitoring device for electrode loss rate of an electrode boiler that can be automatically calibrated. Background Technology

[0002] Electrode boilers, as highly efficient thermal energy conversion devices, are widely used in industrial heating, power peak shaving, and other fields. During the operation of an electrode boiler, the electrodes are in direct contact with the high-temperature medium and energy conversion is achieved through electric current. After long-term use, they will suffer wear and tear due to factors such as electrochemical corrosion, high-temperature oxidation, and mechanical erosion. Electrode wear not only leads to a decrease in boiler thermal efficiency and an increase in energy consumption, but may also cause safety accidents due to damage to the electrode structure.

[0003] Existing electrode wear monitoring methods are mostly offline, involving periodic shutdowns followed by electrode disassembly for dimensional or weight measurements. This method has significant drawbacks: firstly, offline monitoring requires interrupting normal boiler operation, impacting production efficiency; secondly, the long monitoring cycle fails to reflect electrode wear status in real time, potentially missing optimal maintenance opportunities. Some online monitoring devices use a single contact point to detect resistance changes, but factors such as electrode surface oxidation and unstable clamping force can easily lead to large detection errors, and the lack of an effective automatic calibration mechanism makes it difficult to guarantee monitoring accuracy. Furthermore, existing devices suffer from insufficient ease of installation and maintenance, and alarm information transmission is untimely, further limiting their application in actual production. Utility Model Content

[0004] The purpose of this invention is to provide an online monitoring device for electrode loss rate of electrode boilers that can be automatically calibrated, which can effectively solve the technical problem of low offline detection efficiency in existing electrode loss monitoring of electrode boilers.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0006] An online monitoring device for electrode loss rate of an automatically calibrated electrode boiler includes a first clamping unit and a second clamping unit for clamping the upper and lower ends of the electrode. Each clamping unit includes two opposing clamping members. The inner side of each clamping member has an arc-shaped clamping surface adapted to the outer wall of the electrode, and a conductive contact piece is provided on the arc-shaped clamping surface. The conductive contact piece in the first and second clamping units is connected to a resistance detection module via a wire. The resistance detection module applies a detection current to the electrode through the conductive contact piece and collects a voltage signal. The resistance detection module is connected to a corrosion assessment module via a controller. The corrosion assessment module calculates the electrode corrosion loss based on the difference between the corrected real-time resistance value and the initial resistance parameter. The controller is connected to a display and alarm module, which displays the corrosion loss and issues an alarm signal when the loss exceeds a preset threshold.

[0007] Furthermore, the clamping elements in the first clamping unit and the second clamping unit are connected by a spring preload mechanism, which ensures that the arc-shaped clamping surfaces of the two clamping elements maintain a constant clamping force on the electrodes.

[0008] Furthermore, the conductive contact piece provided on the arc-shaped clamping surface has a segmented structure, including an arc-shaped contact piece that adapts to the outer wall of the cylindrical section of the electrode and a planar contact piece that adapts to the transition area of ​​the electrode edge.

[0009] Furthermore, the first clamping unit and the second clamping unit are fixed to the electrode boiler shell by a detachable mounting structure, which includes a slide rail assembly or a quick-release buckle.

[0010] Furthermore, the display alarm module includes an audible and visual alarm and a wireless communication unit, wherein the wireless communication unit is configured to transmit the corrosion loss amount and alarm signal to a remote monitoring terminal.

[0011] Furthermore, the resistance detection module includes a bidirectional constant current source circuit, configured to alternately output forward and reverse detection currents, and the corrosion assessment module takes the average of two measured resistance values ​​as the real-time resistance value.

[0012] Furthermore, the first clamping unit and the second clamping unit are connected by a telescopic insulating connecting rod.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] This invention clamps the upper and lower ends of the electrode using a first clamping unit and a second clamping unit. A stable electrical connection is achieved using conductive contacts on the arc-shaped clamping surface. A resistance detection module applies a detection current and collects a voltage signal through the conductive contacts, calculating the electrode resistance change using Ohm's law. A corrosion assessment module calculates the loss based on the difference between the real-time resistance value and the initial resistance parameter, enabling online real-time monitoring of the electrode loss rate. This invention solves the problems of low efficiency and inability to monitor in real-time using traditional offline detection methods. By correlating resistance changes with loss, it provides accurate data support for electrode maintenance.

[0015] This invention utilizes a spring preload mechanism to maintain a constant clamping force on the electrode, preventing poor contact caused by slight electrode vibration, thermal expansion and contraction, or wear of the clamping component. The constant clamping force ensures stable contact resistance between the conductive contact and the electrode, reducing interference from contact resistance fluctuations on the detected current and voltage signals, improving the accuracy of resistance detection, and solving the problem of low monitoring accuracy caused by unstable clamping force in existing devices.

[0016] This invention relates to a segmented conductive contact plate that is adapted to both the cylindrical section and the edge transition region of an electrode. During operation, the wear rate and morphology differ at different parts of the electrode. The cylindrical section primarily experiences uniform corrosion, while the edge transition region is prone to localized corrosion due to stress concentration. The segmented contact plate ensures good contact at different structural locations on the electrode, avoiding resistance detection deviations caused by improper contact positions and improving the accuracy of assessing the overall electrode wear condition.

[0017] This utility model's detachable installation structure allows the first and second clamping units to be quickly fixed to or removed from the boiler shell, facilitating the installation, debugging, maintenance, and replacement of the device. It solves the problems of cumbersome installation and inconvenient maintenance associated with traditional monitoring devices, reducing the time and cost of equipment installation and maintenance.

[0018] This utility model's audible and visual alarm can promptly issue alarm signals on-site, alerting operators to abnormal electrode wear. The wireless communication unit transmits the wear data and alarm signals to a remote monitoring terminal, enabling remote real-time monitoring. This solution solves the problem of untimely alarm information transmission, ensuring that operators and the remote management center can promptly grasp the electrode status, facilitating rapid maintenance measures and ensuring the safe operation of the boiler.

[0019] This invention features a bidirectional constant current source circuit that alternately outputs forward and reverse detection currents. The corrosion assessment module takes the average of the two measured resistance values ​​as the real-time resistance value. This method effectively compensates for unidirectional errors such as thermoelectric potential caused by temperature differences between the electrodes and contact plates, achieving automatic calibration of resistance detection, improving the measurement accuracy of real-time resistance values, and solving the problem of large detection errors caused by the lack of an effective calibration mechanism in existing devices.

[0020] This utility model features a telescopic insulating connecting rod that connects the first clamping unit and the second clamping unit. The distance between the two clamping units can be adjusted according to electrodes of different lengths, improving the device's adaptability to electrodes of different specifications. At the same time, the insulating connecting rod can avoid electrical interference between the two clamping units, ensuring the independence and accuracy of resistance detection, and solving the problems of poor device adaptability and potential electrical interference. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 This is a block diagram showing the overall structure of the present invention and the connection relationships between its main modules.

[0023] Figure 2 This is a block diagram of the display alarm module of this utility model.

[0024] Figure 3 This is a block diagram illustrating the working principle and connection relationship of the resistance detection module of this utility model.

[0025] Figure 4 This is a diagram showing the state of the first clamping unit and the second clamping unit of this utility model clamping the electrode.

[0026] Figure label:

[0027] 101 First clamping unit, 102 Second clamping unit, 103 Resistance detection module, 104 Controller, 105 Corrosion assessment module, 106 Display and alarm module, 107 Audible and visual alarm, 108 Wireless communication unit, 109 Remote monitoring terminal, 110 Electrode, 111 Connecting rod, 112 Conductive contact piece. Detailed Implementation

[0028] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0029] In the description of the embodiments of this utility model, it should be understood that the terms "length", "vertical", "horizontal", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this utility model.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the embodiments of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0031] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0032] In this embodiment of the invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0033] The following disclosure provides many different implementations or examples for different structures of the embodiments of the present invention. To simplify the disclosure of the embodiments of the present invention, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the embodiments of the present invention. Furthermore, reference numerals and / or reference letters may be repeated in different examples of the embodiments of the present invention; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various implementations and / or arrangements discussed.

[0034] The embodiments of this utility model will now be described in detail with reference to the accompanying drawings.

[0035] Example 1:

[0036] See Figures 1-4 This embodiment discloses a boiler electrode monitoring device, specifically an online monitoring device for the electrode loss rate of an automatically calibrated boiler electrode. It includes a first clamping unit 101 and a second clamping unit 102. The first clamping unit 101 clamps the upper end of an electrode 110, and the second clamping unit 102 clamps the lower end of the electrode 110. Both the first clamping unit 101 and the second clamping unit 102 include two opposing clamping members. The inner side of each clamping member has an arc-shaped clamping surface adapted to the outer wall of the electrode 110. A conductive contact piece 112 is provided on the arc-shaped clamping surface, and the conductive contact piece 112 is made of copper.

[0037] The clamping members in the first clamping unit 101 and the second clamping unit 102 are connected by a spring preload mechanism. The preload force of the spring preload mechanism is 10N, which ensures that the arc-shaped clamping surfaces of the two clamping members maintain a constant clamping force on the electrode 110. The conductive contact piece 112 provided on the arc-shaped clamping surface has a segmented structure, including an arc-shaped contact piece that adapts to the outer wall of the cylindrical section of the electrode 110 and a planar contact piece that adapts to the transition area of ​​the edge of the electrode 110. The curvature of the arc-shaped contact piece is consistent with the curvature of the outer wall of the cylindrical section of the electrode 110, and the area of ​​the planar contact piece is 2cm². 2 .

[0038] Furthermore, the first clamping unit 101 and the second clamping unit 102 are fixed to the boiler shell of the electrode 110 via a slide rail assembly. The slide rail assembly includes a slide rail fixedly connected to the boiler shell and a slider connected to the clamping unit. The slider can slide along the slide rail to adjust the position of the clamping unit.

[0039] Furthermore, the resistance detection module 103 includes a bidirectional constant current source circuit, configured to alternately output a forward 1mA and a reverse 1mA detection current. The conductive contact piece 112 in the first clamping unit 101 and the second clamping unit 102 is connected to the resistance detection module 103 through wires. The resistance detection module 103 is connected to the controller 104 through wires. The controller 104 adopts an STM32 series microcontroller.

[0040] The controller 104 is connected to a corrosion assessment module 105, which pre-stores the initial resistance parameter of the electrode 110, which is 5Ω. The corrosion assessment module 105 uses the average of two resistance values ​​measured by the bidirectional constant current source as the real-time resistance value. When the real-time resistance value is 5.5Ω, it calculates the loss corresponding to a corrosion loss of 0.5Ω for the electrode 110.

[0041] Furthermore, the controller 104 is connected to a display alarm module 106, which includes an audible and visual alarm 107 and a wireless communication unit 108. The wireless communication unit 108 uses a GPRS module and is configured to transmit the corrosion loss amount and alarm signal to the remote monitoring terminal 109. The preset loss threshold is 1Ω. When the loss amount does not exceed the threshold, the display alarm module 106 displays the loss amount in real time; when the loss amount exceeds the threshold, the audible and visual alarm 107 issues an audible and visual alarm, and at the same time, the wireless communication unit 108 transmits the alarm signal to the remote monitoring terminal 109.

[0042] The first clamping unit 101 and the second clamping unit 102 are connected by a telescopic insulating rod 111. The telescopic insulating rod 111 is made of epoxy resin and has a maximum telescopic length of 50cm.

[0043] Example 2

[0044] This embodiment is basically the same as Embodiment 1, except that the preload of the spring preload mechanism is 20N; the bidirectional constant current source circuit alternately outputs a forward 3mA and a reverse 3mA detection current; the initial resistance parameter of electrode 110 is 8Ω, and when the real-time resistance value is 9.2Ω, the corrosion loss of electrode 110 is calculated to be 1.2Ω, corresponding to the loss amount; the preset loss threshold is 1.5Ω; and the maximum telescopic length of the telescopic insulating connecting rod 111 is 80cm. The remaining structure and parameters are the same as in Embodiment 1.

[0045] Example 3:

[0046] This embodiment is basically the same as Embodiment 1, except that the preload of the spring preload mechanism is 30N; the bidirectional constant current source circuit alternately outputs a forward 5mA and a reverse 5mA detection current; the initial resistance parameter of electrode 110 is 10Ω, and when the real-time resistance value is 12Ω, the corrosion loss of electrode 110 is calculated to be 2Ω, corresponding to the loss amount; the preset loss threshold is 2.5Ω; the first clamping unit 101 and the second clamping unit 102 are fixed to the boiler shell of electrode 110 by quick-release buckles; the maximum extension length of the telescopic insulating connecting rod 111 is 100cm. The remaining structure and parameters are the same as in Embodiment 1.

[0047] This invention achieves stable clamping of the electrode 110 through the first clamping unit 101 and the second clamping unit 102. The resistance detection module 103, combined with the bidirectional constant current source, realizes accurate measurement and automatic calibration of resistance. The corrosion assessment module 105 calculates the loss. The display and alarm module 106 realizes on-site and remote alarms. The telescopic insulating connecting rod 111 and the detachable installation structure improve the adaptability and maintenance convenience of the device, effectively solving the problems existing in the current electrode 110 loss monitoring technology.

[0048] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0049] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. It should be noted that any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An online monitoring device for electrode loss rate of an electrode boiler with automatic calibration capability, characterized in that: It includes a first clamping unit and a second clamping unit for clamping the upper end and the lower end. The first clamping unit and the second clamping unit each include two clamping members arranged opposite to each other. The inner side of the clamping member is provided with an arc-shaped clamping surface adapted to the outer wall of the electrode. The arc-shaped clamping surface is provided with a conductive contact piece. In the first and second clamping units, the conductive contact pieces are connected to the resistance detection module via wires. The resistance detection module is used to apply a detection current to the electrode through the conductive contact pieces and to acquire a voltage signal. The resistance detection module is connected to a corrosion assessment module via a controller. The corrosion assessment module is used to calculate the electrode corrosion loss based on the difference between the corrected real-time resistance value and the initial resistance parameter. The controller is connected to a display and alarm module, which is used to display the corrosion loss and issue an alarm signal when the loss exceeds a preset threshold.

2. The online monitoring device for electrode loss rate of an automatically calibrated electrode boiler according to claim 1, characterized in that: The clamping components in the first clamping unit and the second clamping unit are connected by a spring preload mechanism, which ensures that the arc-shaped clamping surfaces of the two clamping components maintain a constant clamping force on the electrodes.

3. The online monitoring device for electrode loss rate of an automatically calibrated electrode boiler according to claim 1, characterized in that: The conductive contact piece on the arc-shaped clamping surface has a segmented structure, including an arc-shaped contact piece that adapts to the outer wall of the cylindrical section of the electrode and a planar contact piece that adapts to the transition area of ​​the electrode edge.

4. The online monitoring device for electrode loss rate of an automatically calibrated electrode boiler according to claim 1, characterized in that: The first clamping unit and the second clamping unit are fixed to the electrode boiler shell by a detachable mounting structure, which includes a slide rail assembly or a quick-release buckle.

5. The online monitoring device for electrode loss rate of an automatically calibrated electrode boiler according to claim 1, characterized in that: The display alarm module includes an audible and visual alarm and a wireless communication unit. The wireless communication unit is configured to transmit the corrosion loss amount and alarm signal to a remote monitoring terminal.

6. The online monitoring device for electrode loss rate of an automatically calibrated electrode boiler according to claim 1, characterized in that: The first clamping unit and the second clamping unit are connected by a telescopic insulating rod.

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