A multi-stage dynamic early warning device for gas purity based on dual-channel infrared spectrum

Abstract

The utility model provides a kind of gas purity multistage dynamic early warning device based on double channel infrared spectrum, belong to gas purity detection technical field, including shell, air inlet device, gas detection device, tail gas treatment device and control device, gas detection device, tail gas treatment device and control device are set in shell, air inlet device is connected with gas detection device, air inlet device is detected with the sulfur hexafluoride gas conveying into gas detection device, gas detection device detects the sulfur hexafluoride gas of entering, and detection data is given control device, tail gas treatment device is connected with gas detection device. Form real-time calibration system by double channel infrared spectrum design, one-way detection target gas, another way as reference standard, temperature, humidity fluctuation and light path pollution can be synchronously captured Interference, after signal comparison compensation, the detection stability under complex working condition is greatly improved, especially suitable for the accurate identification of trace impurities in sulfur hexafluoride and other special gas recovery.

Description

Technical Field

[0001] This utility model relates to the field of gas purity detection technology, and in particular to a multi-level dynamic early warning device for sulfur hexafluoride gas purity based on dual-channel infrared spectroscopy. Background Technology

[0002] In the field of electrical engineering, sensing and detection technology serves as a core bridge connecting the physical world and digital systems. Essentially, it converts non-electrical physical quantities (such as temperature, pressure, light intensity, and gas concentration) into measurable electrical signals using various sensors, and then extracts key information using signal processing techniques. Employing advanced sensing technologies such as infrared spectroscopy and electron capture (ECD) principles, the concentration of sulfur hexafluoride (SF6) gas can be accurately measured, ensuring precise control of gas purity during the recovery process and improving recovery efficiency. By installing an online monitoring and alarm system for SF6 gas leaks, gas leaks can be monitored in real time, allowing for timely detection and handling of leaks and preventing gas waste. While sulfur hexafluoride (SF6) gas recovery devices facilitate the recycling of SF6 from power equipment, several significant drawbacks remain. From a cost perspective, their efficient sensing and detection technology is a core advantage, but it also brings a high economic burden: key components such as high-precision sensors and intelligent detection modules rely on specialized manufacturing processes, resulting in significantly higher initial purchase costs compared to traditional recovery equipment. Furthermore, maintaining detection accuracy and equipment performance requires ongoing investment in component calibration and system maintenance, placing pressure on long-term operational costs. System complexity is another major challenge. The device needs to achieve coordinated operation across multiple stages, including gas collection, purity detection, and compression storage. The integration of different modules involves complex processes such as hardware compatibility and software debugging, often requiring the full involvement of qualified technical personnel. Daily calibration work demands extremely high operational precision, which is beyond the capabilities of ordinary maintenance personnel, increasing labor costs and potentially affecting recovery efficiency due to improper operation. There are certain contradictions regarding the environmental impact: Although the device reduces direct emissions of sulfur hexafluoride (SF6) through precise recovery, SF6 itself is a potent greenhouse gas with a global warming potential thousands of times greater than carbon dioxide. If equipment sealing is inadequate or pipeline leaks occur during the recovery process, gas escape may still occur. Furthermore, current recovery technologies cannot achieve 100% purity treatment, and the final disposal of residual gas still poses potential environmental risks. In addition, the equipment is highly dependent on external conditions. The recovery process requires a stable power supply to ensure the operation of equipment such as vacuum compressors and circulation pumps. Power outages or voltage fluctuations may lead to recovery interruptions. The stability of core components such as compressors and valves directly affects the continuity of the process; malfunctions not only reduce recovery efficiency but may also cause safety hazards due to gas stagnation in pipelines, further increasing operational difficulty. These shortcomings collectively restrict the widespread application and effective utilization of SF6 gas recovery devices.

[0003] The existing technology mainly has the following problems: Firstly, single-channel infrared detection systems are vulnerable to environmental interference. Temperature instability can cause wavelength shifts in the infrared light source, drastic humidity changes alter the refractive index of the optical path medium, and particulate matter deposition during gas flow through the detection chamber can cause scattering loss in the optical path. These factors combined lead to a significant decrease in the stability of the detection signal. In scenarios requiring high purity, such as sulfur hexafluoride, this interference can significantly reduce the detection accuracy of trace impurities, making it difficult to meet the stringent purity analysis standards for recycling and reuse. Secondly, traditional early warning mechanisms employ a single threshold triggering mode, issuing alarms only at a fixed purity critical point. This fails to match the dynamic characteristics of gradual purity changes during gas recovery. In actual recovery, gas purity gradually increases from low to high. A single threshold either frequently triggers unnecessary shutdowns at low purity levels, causing false alarms, or, at high purity levels, the threshold is set too high, resulting in delayed warnings and allowing substandard gas to enter the storage stage. This rigid response mode severely reduces recovery efficiency, especially during mixed gas separation. Third, the anti-interference design of traditional systems has structural defects. Optical components are prone to performance degradation after long-term operation. For example, the anti-reflection film of the infrared window will reduce its light transmittance due to gas corrosion, and the response performance of the thermoelectric detector will drift due to power instability, ultimately leading to a decrease in the stability of the detection baseline. To maintain detection accuracy, frequent manual calibration is necessary, and each calibration requires interrupting the recovery process. This not only significantly increases annual maintenance costs but also allows excessive gases to be emitted directly without effective monitoring due to detection interruptions, creating potential safety hazards. Fourth, the linkage between the early warning system and the recovery equipment is limited to simple alarm functions and lacks closed-loop control logic. When an abnormal purity is detected, operators must manually adjust key parameters of the recovery device, such as valve opening and compression power. There is a significant response delay from the detection of the abnormality to the completion of the adjustment. During this period, substandard gas may continue to enter the purification module, causing adsorbent overload and failure. If the operator misjudges the situation, high-pressure gas leakage may also occur due to misoperation, posing a safety threat to surrounding equipment and personnel. Utility Model Content

[0004] The purpose of this invention is to provide a multi-level dynamic early warning device for gas purity based on dual-channel infrared spectroscopy, solving the technical problems existing in current gas purity detection and early warning technologies. Addressing the technical pain points in the recovery and treatment of special gases such as sulfur hexafluoride, this invention provides a high-precision, high-reliability dynamic early warning solution.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A multi-level dynamic early warning device for gas purity based on dual-channel infrared spectroscopy includes a housing, an air inlet device, a gas detection device, an exhaust gas treatment device, and a control device. The gas detection device, exhaust gas treatment device, and control device are housed within the housing. The air inlet device is connected to the gas detection device, which delivers the detected sulfur hexafluoride gas into the gas detection device. The gas detection device detects the incoming sulfur hexafluoride gas and transmits the detection data to the control device. The exhaust gas treatment device is connected to the gas detection device and filters the sulfur hexafluoride gas at the tail end.

[0006] Furthermore, the housing includes an outer shell, a real-time monitoring data display screen, a green indicator light, a red indicator light, a power switch, and a handle. The handle is located on the top of the outer shell, the real-time monitoring data display screen is located on the outer shell and connected to the control device, the green indicator light and the red indicator light are located on the outer shell and connected to the control device, and the power switch is connected to the control device to control the power switch.

[0007] Furthermore, the air intake device includes a gas recovery probe, a tube, and a pump. One end of the tube is connected to one end of the gas recovery probe, the other end of the gas recovery probe is connected to the end that extracts the gas to be measured, and the other end of the tube is connected to the pump.

[0008] Furthermore, the gas detection device includes a gas detection chamber and a dual-channel infrared spectroscopy module. The dual-channel infrared spectroscopy module is installed inside the gas detection chamber and is connected to the control device. The gas detection chamber is connected to the exhaust gas treatment device.

[0009] Furthermore, the exhaust gas treatment device includes a transmission pipe and an exhaust gas processor, the exhaust gas processor being connected to a gas detection box via the transmission pipe.

[0010] Furthermore, the dual-channel infrared spectroscopy module includes a gas detection sensor, a filter circuit, a detection circuit, and a differential amplifier circuit. The gas detection sensor is connected to the detection circuit via the filter circuit, the detection circuit is connected to the differential amplifier circuit, and the differential amplifier circuit is connected to the control device.

[0011] Furthermore, the control device uses an STM32 series microcontroller minimum system, an environmental temperature and humidity detection sensor, and a storage circuit. The humidity detection sensor and the storage circuit are both connected to the STM32 series microcontroller minimum system via I / O ports. The environmental temperature and humidity detection sensor detects real-time environmental temperature and humidity data and transmits it to the STM32 chip. The STM32 chip embeds the existing Beer-Lambert law differential logarithm processing algorithm to perform real-time calculations on the two spectral data and eliminates environmental influences according to the existing Beer-Lambert law formula.

[0012] This utility model, by adopting the above-mentioned technical solution, has the following beneficial effects: (1) This utility model forms a real-time calibration system through dual-channel infrared spectroscopy design. One channel detects the target gas, and the other channel serves as a reference standard. It can simultaneously capture interference such as temperature and humidity fluctuations and light path contamination. After signal comparison and compensation, it greatly improves the detection stability under complex working conditions, and is especially suitable for the accurate identification of trace impurities in the recovery of special gases such as sulfur hexafluoride.

[0013] (2) Construct a closed-loop control system for equipment linkage. When abnormal purity is detected, output control commands directly and automatically adjust the core parameters of the recovery equipment to achieve seamless connection between abnormal detection and process adjustment, shorten response delay, reduce manual intervention, and avoid safety hazards such as unqualified gas damaging the purification module and human operation errors. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the device structure of this utility model; Figure 2 This is the circuit block diagram of this utility model; Figure 3 This is the circuit schematic diagram of the dual-channel infrared spectroscopy module of this utility model.

[0015] In the attached diagram, 1-outer shell, 2-real-time monitoring data display screen, 3-green indicator light, 4-red indicator light, 5-power switch, 6-handle, 7-recovery gas probe, 8-pipe, 9-vacuum pump, 10-gas detection unit, 11-transmission pipe, 12-exhaust gas processor. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided with reference to the accompanying drawings and preferred embodiments. However, it should be noted that many details listed in the specification are merely to provide the reader with a thorough understanding of one or more aspects of this utility model, and these aspects can be achieved even without these specific details.

[0017] like Figure 1 As shown, a multi-level dynamic early warning device for gas purity based on dual-channel infrared spectroscopy includes a housing, an air inlet device, a gas detection device, an exhaust gas treatment device, and a control device. The gas detection device, exhaust gas treatment device, and control device are disposed inside the housing. The air inlet device is connected to the gas detection device, which delivers the detected sulfur hexafluoride gas to the gas detection device. The gas detection device detects the incoming sulfur hexafluoride gas and transmits the detection data to the control device. The exhaust gas treatment device is connected to the gas detection device and filters the sulfur hexafluoride gas at the tail end.

[0018] In this embodiment of the utility model, such as Figure 1As shown, the housing includes an outer shell 1, a real-time monitoring data display screen 2, a green indicator light 3, a red indicator light 4, a power switch 5, and a handle 6. The handle 6 is located on the top of the outer shell 1. The real-time monitoring data display screen 2 is located on the outer shell 1 and is connected to the control device. The green indicator light 3 and the red indicator light 4 are located on the outer shell 1 and are connected to the control device. The power switch 5 is connected to the control device and controls the power switch.

[0019] In this embodiment of the utility model, such as Figure 1 As shown, the air intake device includes a gas recovery probe 7, a tube 8, and a vacuum pump 9. One end of the tube 8 is connected to one end of the gas recovery probe 7, the other end of the gas recovery probe 7 is connected to the end of the gas to be extracted, and the other end of the tube 8 is connected to the vacuum pump 9.

[0020] In this embodiment of the utility model, such as Figure 1 As shown, the gas detection device includes a gas detection chamber and a dual-channel infrared spectroscopy module. The dual-channel infrared spectroscopy module is installed inside the gas detection chamber and is connected to the control device. The gas detection chamber is connected to the exhaust gas treatment device.

[0021] In this embodiment of the utility model, such as Figure 1 As shown, the exhaust gas treatment device includes a transmission pipe 11 and an exhaust gas processor 12, which is connected to a gas detection box via the transmission pipe 11. The exhaust gas processor 12 uses an existing SF6 gas filter.

[0022] In this embodiment of the utility model, such as Figure 3 As shown, the dual-channel infrared spectroscopy module includes a gas detection sensor, a filter circuit, a detection circuit, and a differential amplifier circuit. The gas detection sensor is connected to the detection circuit via the filter circuit, the detection circuit is connected to the differential amplifier circuit, and the differential amplifier circuit is connected to the control device. The gas detection sensor is a GZG363 type dual-channel SF6 gas sensor.

[0023] In this embodiment of the utility model, such as Figure 2 As shown, the control device uses an STM32 series microcontroller minimum system, an environmental temperature and humidity detection sensor, and a storage circuit. The humidity detection sensor and the storage circuit are both connected to the STM32 series microcontroller minimum system via I / O ports. The environmental temperature and humidity detection sensor detects real-time environmental temperature and humidity data and transmits it to the STM32 chip. The STM32 chip embeds the existing Beer-Lambert law differential logarithm processing algorithm to perform real-time calculations on the two spectral data and eliminates environmental influences according to the existing Beer-Lambert law formula.

[0024] The outer casing 1 provides integrated protection, and the handle 6 is attached to it for portable deployment. The real-time monitoring data display screen 2, located on the upper side of the casing 1, displays data in real time. To the right of the display screen 2 are green indicator lights 3 (in operation) and red indicator lights 4 (stopped operation), arranged vertically with green indicator lights 3 on top and red indicator lights 4 on the bottom. A lit green indicator light 3 indicates operation, while a lit red indicator light 4 indicates a fault. The power switch 5, located in the upper right corner of the side with the real-time monitoring data display screen 2, controls the on / off state. The recovered gas probe 7 and tube 8 form a single sampling end, connected to the vacuum pump 9, located on the lower left rear corner of the casing 1. The vacuum pump 9 provides the suction power. Inside the outer casing 1 are the outer casing gas detection unit 10, the transmission pipe 11, and the exhaust gas processor 12, which are connected as one unit and fill the interior of the outer casing 1. The transmission pipe 11 is located between the outer casing gas detection unit 10 and the exhaust gas processor 12. The outer casing gas detection unit 10 has a built-in dual-channel infrared spectroscopy module. The transmission pipe 11 is used to transmit the recovered gas after it has been detected in the outer casing gas detection unit 10 to the exhaust gas processor 12.

[0025] The dual-channel infrared spectroscopy detection module is the core component for achieving accurate detection. One channel is dedicated to detecting the characteristic infrared band of the gas to be tested, capturing changes in the light signal in this band to obtain a characteristic spectral signal that reflects the gas's properties. The other channel selects a reference band that is not absorbed by the gas, continuously acquiring a stable reference spectral signal. The signals from these two channels do not exist independently, but rather form effective complementarity and calibration through an internal comparative analysis mechanism. This comparison directly eliminates the influence of various interference factors such as temperature fluctuations, humidity changes, and the instability of the light source itself, thereby significantly improving the accuracy of gas component detection. It also ensures that the detection results maintain good stability under different environmental conditions, continuously outputting reliable detection data even in complex environments such as industrial sites. The data processing module, as the core processing unit of the device, immediately activates a preset existing algorithm model to deeply analyze the signal after receiving the spectral signal from the dual-channel infrared spectroscopy detection module. The existing algorithm model first obtains the specific concentration value of the target component in the gas through feature extraction and calculation of the spectral signal, and then converts the concentration value into an intuitive gas purity parameter based on the correspondence between concentration and purity. In addition, the module has two key functions: the data filtering function can effectively filter out instantaneous interference signals that occur during the detection process, such as circuit noise and instantaneous airflow fluctuations, to ensure that the output data is true and reliable; the trend analysis function can keenly identify the changing trend of gas purity by tracking and analyzing continuous detection data. Whether it is a slow decrease or a sudden fluctuation, it can be captured and recorded in time, providing a strong reference for subsequent judgment and decision-making.

[0026] The multi-level dynamic early warning module is a crucial component ensuring the safe operation of the device. Its chip has three pre-set purity thresholds, each corresponding to different levels of abnormality. It receives gas purity values ​​from the data processing module in real time and compares them to the preset thresholds, automatically matching them to the corresponding threshold range. When the purity value falls within a different range, the device triggers the corresponding level of early warning mechanism: For a Level 1 warning, the device uses a specific flashing indicator light to alert personnel to the equipment status; for a Level 2 warning, the audible and visual alarm system is triggered simultaneously, using both sound and light to enhance the warning effect and prompt timely action; for a Level 3 warning, the module immediately outputs a switching signal, directly linking relevant valves and exhaust devices to initiate proactive intervention operations such as valve closure and exhaust activation. This forms a complete closed-loop protection system from early warning to automatic control, minimizing the potential risks posed by gas anomalies. The device also features comprehensive data storage and communication capabilities. A 4G module can be added to the circuitry to enable real-time wireless communication with user equipment. The data storage function can record historical purity data, the time and level of each warning, and other information long-term. This data can be retrieved at any time, providing detailed raw data for equipment maintenance, troubleshooting, and production analysis. The communication function uploads real-time detection data and equipment status information to the monitoring platform via a standard interface, allowing managers to query data and control equipment remotely. This enables real-time monitoring of the device's operating status and allows for parameter adjustments or command issuance based on actual conditions, fully meeting the needs of centralized management of multiple devices in industrial scenarios and improving management efficiency and response speed.

[0027] The early warning mechanism breaks through the single threshold mode and adopts multi-level dynamic logic. It sets multiple gradient thresholds according to the purity change, corresponding to different early warning intensities and processing strategies. It optimizes preprocessing in the low purity stage and initiates strong intervention in the high purity critical state, which is perfectly adapted to the scenario of dynamic purity change in recycling, reducing false alarms and delays.

[0028] Operating Procedures: After powering on, the device starts up, and its main control system inside the casing is powered on. If the green indicator light remains constantly on, it indicates that the device has entered the "ready to run" state. If startup fails, such as due to a circuit fault, the red indicator light will flash, prompting troubleshooting. The gas detection unit will first perform dual-channel initialization calibration, matching the baseline of the reference channel with the detection channel to eliminate initial deviations in the light source and circuitry, laying a solid foundation for subsequent accurate detection. After starting the pump unit, it uses a tube to drive the recovery gas probe to draw in the gas to be tested, forming a stable airflow. When the airflow enters the gas detection unit, the dual-channel infrared modules work simultaneously, capturing the infrared characteristic absorption signal of the target gas and converting it into a concentration-related electrical signal; simultaneously, signals in the non-absorption band under the same environment are collected to cancel environmental interference in real time. After processing, the effects of temperature and humidity are canceled out, and the gas purity data is extracted and synchronously fed back to the real-time monitoring data display screen.

[0029] The device operates in two states: normal and abnormal. When the equipment is stable and the gas purity meets the standard, with the detected value within the preset "qualified range," the system triggers closed-loop regulation, automatically optimizing the pumping rate of the pump unit and the detection status of the gas detection unit to ensure stability. At this time, the green indicator light remains constantly lit, and the "normal operation" status is simultaneously reflected on the real-time monitoring data display screen. When the gas purity deviates from the qualified range, the equipment is in an abnormal state, and the system activates a three-level warning mechanism based on the degree of deviation. The first-level warning indicates a minor abnormality; the green indicator light flashes frequently, and the real-time monitoring data display screen displays a "Recommend checking equipment / gas source" message. The system retains operating parameters and continuously monitors the gas state change trend. The second-level warning indicates a moderate abnormality; the pump unit automatically reduces its speed to decrease the amount of abnormal gas extracted. The gas flow is directed through the transmission pipe to the exhaust gas processor, activating the "deceleration and recovery" mode to reduce the risk of external discharge. The display screen simultaneously shows the "recovering" status. A Level 3 warning indicates a severe anomaly. The system will immediately shut down, the red indicator light will remain on, the pump unit will be powered off and stop, the external valves will be activated to cut off the gas supply, an audible and visual alarm will be triggered, and the exhaust gas processor will operate at full power to ensure that the residual gas is purified in compliance with regulations.

[0030] Any matters not covered in this utility model are common knowledge.

[0031] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A multi-level dynamic early warning device for gas purity based on dual-channel infrared spectroscopy, characterized in that: It includes a housing, an air intake device, a gas detection device, an exhaust gas treatment device, and a control device. The gas detection device, exhaust gas treatment device, and control device are housed inside the housing. The air intake device is connected to the gas detection device and delivers the detected sulfur hexafluoride gas to the gas detection device. The gas detection device detects the incoming sulfur hexafluoride gas and transmits the detection data to the control device. The exhaust gas treatment device is connected to the gas detection device and filters the sulfur hexafluoride gas at the tail end.

2. The gas purity multi-level dynamic early warning device based on dual-channel infrared spectroscopy according to claim 1, characterized in that: The housing includes an outer shell (1), a real-time monitoring data display screen (2), a green indicator light (3), a red indicator light (4), a power switch (5), and a handle (6). The handle (6) is located on the top of the outer shell (1). The real-time monitoring data display screen (2) is located on the outer shell (1) and connected to the control device. The green indicator light (3) and the red indicator light (4) are located on the outer shell (1) and connected to the control device. The power switch (5) is connected to the control device and controls the power switch.

3. The gas purity multi-level dynamic early warning device based on dual-channel infrared spectroscopy according to claim 1, characterized in that: The air intake device includes a gas recovery probe (7), a tube (8) and a pump (9). One end of the tube (8) is connected to one end of the gas recovery probe (7), the other end of the gas recovery probe (7) is connected to the end of the gas to be extracted, and the other end of the tube (8) is connected to the pump (9).

4. The gas purity multi-level dynamic early warning device based on dual-channel infrared spectroscopy according to claim 1, characterized in that: The gas detection device includes a gas detection chamber and a dual-channel infrared spectroscopy module. The dual-channel infrared spectroscopy module is installed inside the gas detection chamber and is connected to the control device. The gas detection chamber is connected to the exhaust gas treatment device.

5. The gas purity multi-level dynamic early warning device based on dual-channel infrared spectroscopy according to claim 1, characterized in that: The exhaust gas treatment device includes a transmission pipe (11) and an exhaust gas processor (12), which is connected to the gas detection box through the transmission pipe (11).

6. The gas purity multi-level dynamic early warning device based on dual-channel infrared spectroscopy according to claim 4, characterized in that: The dual-channel infrared spectroscopy module includes a gas detection sensor, a filter circuit, a detection circuit, and a differential amplifier circuit. The gas detection sensor is connected to the detection circuit via the filter circuit, the detection circuit is connected to the differential amplifier circuit, and the differential amplifier circuit is connected to the control device.

7. The gas purity multi-level dynamic early warning device based on dual-channel infrared spectroscopy according to claim 1, characterized in that: The control device uses an STM32 series microcontroller minimum system, an environmental temperature and humidity detection sensor, and a storage circuit. The humidity detection sensor and the storage circuit are both connected to the STM32 series microcontroller minimum system via I / O ports. The environmental temperature and humidity detection sensor detects real-time environmental temperature and humidity data and transmits it to the STM32 chip. The STM32 chip embeds the existing Beer-Lambert law differential logarithm processing algorithm to perform real-time calculations on the two spectral data and eliminates environmental influences according to the existing Beer-Lambert law formula.

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