A water-cooled beam flow monitoring system for a heating furnace

Abstract

This utility model belongs to the field of industrial heating furnace safety monitoring technology, and specifically relates to a water-cooled beam flow monitoring system for heating furnaces. It includes a magnetically attached temperature-sensing resistor fastened to the surface of the drain pipe via a stainless steel strip, with the contact surface coated with thermally conductive silicone grease. The magnetically attached temperature-sensing resistor is connected to a wireless temperature transmitter via a high-temperature cable. The wireless temperature transmitter communicates wirelessly with a WiFi gateway via an RF antenna. The WiFi gateway is connected to a cloud server via an Internet of Things (IoT) network. The cloud server is connected to computer terminals, mobile phone terminals, and tablet terminals via networks. By indirectly determining the flow status through temperature monitoring, early warning of water-cooled beam blockage faults can be achieved, reducing equipment failure rates and maintenance costs, and improving the safety and reliability of heating furnace operation.

Description

Technical Field

[0001] This utility model belongs to the field of industrial heating furnace safety monitoring technology, and specifically relates to a heating furnace water-cooled beam flow monitoring system, which is suitable for early warning of blockage faults and flow status monitoring of heating furnace water-cooled beams in industrial environments such as high temperature, strong electromagnetic interference, and gas explosion prevention. Background Technology

[0002] In existing technologies, the water-cooled beam of a heating furnace is a key cooling component of an industrial heating furnace, and its normal operation directly affects the safety and production efficiency of the furnace. The water-cooled beam removes heat through circulating water, preventing the furnace body from deforming and collapsing. Previously, the drain pipe of the water-cooled beam of the heating furnace was not equipped with any blockage detection elements. Operators mainly relied on periodically and manually draining wastewater and observing whether water was flowing out of the drain pipe to determine if the water pipe was blocked.

[0003] Traditional detection methods have several drawbacks: 1. Lack of real-time monitoring. Relying on periodic manual inspections creates blind spots, failing to detect abnormal water-cooled beam flow and potential blockages in a timely manner. 2. Delayed fault detection. By the time abnormal discharge is detected, the water-cooled beam may already be severely blocked, or even experiencing localized overheating and deformation. 3. High maintenance costs. Faults require shutdown for repairs, resulting in high maintenance costs and prolonged downtime, leading to significant economic losses. 4. Poor safety. Blockage in the water-cooled beam can trigger major safety accidents such as furnace collapse, seriously threatening production and personnel safety. Therefore, there is an urgent need for a device capable of real-time, automatic, and accurate detection of the flow status of the water-cooled beams in the heating furnace to address the aforementioned problems in existing technologies. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a flow monitoring system for water-cooled beams in a heating furnace. By indirectly determining the flow status through temperature monitoring, it enables early warning of blockage faults in the water-cooled beams, reducing equipment failure rates and maintenance costs, and improving the safety and reliability of the heating furnace operation.

[0005] The technical solution of this utility model is: a flow monitoring system for water-cooled beams in a heating furnace, characterized by comprising:

[0006] Temperature acquisition: A magnetic temperature measuring resistor is installed at the outlet end of the drain pipe of the water-cooled beam of the heating furnace. Thermal grease is placed between the magnetic temperature measuring resistor and the drain pipe. The magnetic temperature measuring resistor and thermal grease are fastened to the surface of the drain pipe by a stainless steel strip.

[0007] Wireless transmission: The magnetic temperature measuring resistor is connected to the wireless temperature measuring transmitter via a cable. Through the built-in wireless module, it transmits data packets to the Internet of Things gateway via radio frequency.

[0008] Gateway processing: After receiving the data packet, the gateway performs data verification and protocol conversion, encapsulates the data into a format that the cloud platform can recognize, and uploads it to the IoT cloud platform via the 4G / 5G network;

[0009] Cloud analytics: After receiving data, the cloud platform performs storage, analysis, and visualization processing, and compares it with preset thresholds to determine whether there are any anomalies.

[0010] Application demonstration and control: Under normal conditions, the water temperature value and curve are displayed in real time on the PC / APP, and historical data is recorded; under abnormal conditions, multi-level alarms are triggered immediately, and notifications are pushed to maintenance personnel. At the same time, control signals can be automatically sent to the heating furnace PLC to adjust the heating status or activate the protection mechanism.

[0011] The advantages of this invention are: 1. Real-time monitoring. By using wireless temperature measurement and IoT technology, the temperature of the drain pipe of the water-cooled beam is collected in real time, indirectly determining the flow status, thus solving the problem that existing technologies cannot monitor in real time. 2. Early fault warning. Through temperature anomaly analysis, faults can be predicted in advance before blockages occur in the water-cooled beam, avoiding equipment damage and safety accidents.

[0012] 3. Reduce maintenance costs. Early detection and handling of faults eliminate the need for additional debugging by professional personnel, allowing for rapid restoration of equipment operation and significantly reducing maintenance costs and equipment downtime.

[0013] 4. Easy Installation. The magnetic temperature sensor and wireless transmitter are easy to install. The wireless transmitter uses a magnetic base, allowing it to be directly attached to nearby steel structures without the need for power cables, making it especially suitable for high-temperature and gas explosion-proof areas. 5. Stable Signal Transmission. High-frequency signals have excellent penetration performance, ensuring good data transmission. After being received in the instrument room, the signal is transmitted to the server via WiFi.

[0014] 6. Strong data traceability. The cloud server can store at least one year's worth of temperature monitoring curves, providing data support for equipment maintenance and process optimization. 7. Diverse terminal support. Supports real-time monitoring from various networked devices such as mobile phones, tablets, and computers, fully leveraging the advantages of the Internet of Things (IoT) and offering convenient operation. 8. Low power consumption and long lifespan. The wireless transmitter adopts an industrial-standard design with a built-in battery, offering a conservative lifespan of up to two years, requiring minimal maintenance and incurring low costs. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model.

[0016] In the diagram: 1-Magnetic temperature measuring resistor, 2-Thermal conductive silicone grease, 3-Stainless steel strip, 4-Drainage pipe, 5-High temperature cable, 6-Wireless temperature measuring transmitter, 7-RF antenna, 8-WiFi gateway, 9-Cloud server, 10-Computer terminal, 11-Mobile terminal, 12-Tablet terminal. Detailed Implementation

[0017] See Figure 1 A water-cooled beam flow monitoring system for a heating furnace has a workflow that can be divided into five key steps: data acquisition, transmission, processing, display, and control, forming an automated monitoring closed loop.

[0018] Temperature acquisition: A magnetic temperature measuring resistor (wireless temperature sensor) is installed at the outlet of the drain pipe of the water-cooled beam of the heating furnace. Thermal grease is placed between the magnetic temperature measuring resistor and the drain pipe. The magnetic temperature measuring resistor and thermal grease are fastened to the surface of the drain pipe by a stainless steel strip. The water temperature of the heating furnace is collected at a preset frequency (adjustable from 10 seconds to 60 minutes). The MCU converts the electrical signal of the temperature measuring element into a digital temperature value and packages it into a data packet containing the sensor ID.

[0019] Wireless transmission: The magnetic temperature measuring resistor is connected to the wireless temperature measuring transmitter via a high-temperature cable. Through the built-in wireless module, the data packets are transmitted wirelessly via radio frequency. The signal penetrates obstacles in the industrial environment and is transmitted to the Internet of Things gateway.

[0020] Gateway processing: After receiving the data packet, the gateway performs data verification (to ensure integrity), protocol conversion, encapsulates the data into a format that the cloud platform can recognize, and uploads it to the IoT cloud platform via the 4G / 5G network.

[0021] Cloud-based analytics: After receiving data, the cloud platform stores, analyzes, and visualizes the data, comparing it against preset thresholds to determine if there are any anomalies.

[0022] Application demonstration and control:

[0023] Normal state: The water temperature value and curve are displayed in real time on the PC / APP, and historical data is recorded.

[0024] Abnormal state: Immediately triggers multi-level alarms and pushes notifications to maintenance personnel. At the same time, it can automatically send control signals to the heating furnace PLC to adjust the heating status or activate the protection mechanism.

[0025] Connection Relationship: The magnetic temperature sensing resistor 1 is fastened to the surface of the sewage pipe 4 via a stainless steel strip 3, and the contact surface is coated with thermally conductive silicone grease 2. The magnetic temperature sensing resistor 1 is connected to the wireless temperature measuring transmitter 6 via a high-temperature cable 5. The wireless temperature measuring transmitter 6 communicates wirelessly with the WiFi gateway 8 via an RF antenna 7. The WiFi gateway 8 is connected to the cloud server 9 via an IoT network. The cloud server 9 is connected to the network of computer terminal 10, mobile phone terminal 11, and tablet terminal 12 respectively.

[0026] Working principle: The wireless temperature measurement and IoT detection system for heating furnace water temperature is an industrial IoT solution that achieves real-time acquisition, transmission, analysis, early warning, and remote control of heating furnace water temperature through a full-link architecture of temperature sensing → wireless transmission → IoT gateway → cloud platform → application terminal.

[0027] Instructions for use: Temperature measurement point selection: Set a temperature monitoring point at the outlet end of the drain pipe of the water-cooled beam of the heating furnace. The temperature change at this location best reflects the flow status of the water-cooled beam.

[0028] Sensor selection and installation: A PT100 magnetic temperature sensor is selected, with a temperature range of -200℃ to 650℃ and an accuracy of ±0.1℃. The temperature sensor is secured to the surface of the drain pipe using a stainless steel strap. The contact surface is coated with high-temperature resistant thermally conductive silicone grease with a thermal conductivity ≥1.5W / (m·K) to ensure tight contact between the temperature sensor and the pipe and good heat conduction.

[0029] Wireless temperature transmitter configuration: The wireless temperature transmitter adopts an industrial-grade design with an IP65 protection rating. It integrates an STM32 microcontroller and a LoRa wireless communication module, operates at a frequency of 433MHz, has a transmission power of 10dBm, and a communication distance of up to 1km. The transmitter connects to the temperature sensing resistor via a high-temperature cable with a temperature resistance rating of 200℃.

[0030] Data Acquisition and Transmission: The wireless temperature transmitter acquires temperature data at a preset frequency (30 seconds / time). The MCU converts the analog temperature signal into a digital temperature signal with a resolution of 0.01℃, performs CRC check encoding, and generates a data packet containing the sensor ID, temperature value, and acquisition time. The transmitter transmits the data packet to the instrument room's WiFi gateway via an RF antenna.

[0031] Gateway processing and uploading: The WiFi gateway adopts an industrial-grade dual-band WiFi module, supporting 2.4GHz / 5GHz frequency bands. After receiving data packets, it performs data verification. Once confirmed to be correct, it converts the data from LoRa protocol to MQTT protocol and uploads it to the cloud server through the factory WiFi network. The upload frequency is synchronized with the acquisition frequency.

[0032] Cloud-based data analysis and early warning: The cloud server uses Alibaba Cloud servers, configured with 8 cores and 16GB of memory, running a temperature monitoring cloud platform. The platform has preset temperature thresholds: the normal operating temperature range is 25℃~60℃, the warning temperature is 65℃, and the alarm temperature is 75℃. When the detected temperature exceeds the warning temperature, the platform pushes warning information via SMS and the APP. When the temperature exceeds the alarm temperature, the platform triggers an audible and visual alarm and sends a signal to the heating furnace PLC control system, prompting operators to take timely action.

[0033] Data display and query: The cloud platform provides web and mobile app services. Operation and maintenance personnel can view temperature values ​​and temperature curves in real time, query historical data (up to 1 year), and export data reports through devices such as computers, mobile phones, and tablets.

[0034] Troubleshooting: Upon receiving the warning information, maintenance personnel analyze the flow status of the water-cooled beam through the temperature curve to determine the degree of blockage, promptly arrange maintenance, clean the sewage pipes, eliminate the blockage, and prevent the water-cooled beam from deforming and collapsing due to lack of cooling.

Claims

1. A fired heater water cooled leg flow monitoring system characterized by include: Temperature acquisition: A magnetic temperature measuring resistor is installed at the outlet end of the drain pipe of the water-cooled beam of the heating furnace. Thermal grease is placed between the magnetic temperature measuring resistor and the drain pipe. The magnetic temperature measuring resistor and thermal grease are fastened to the surface of the drain pipe by a stainless steel strip. Wireless transmission: The magnetic temperature measuring resistor is connected to the wireless temperature measuring transmitter via a cable. Through the built-in wireless module, it transmits data packets to the Internet of Things gateway via radio frequency. Gateway processing: After receiving the data packet, the gateway performs data verification and protocol conversion, encapsulates the data into a format that the cloud platform can recognize, and uploads it to the IoT cloud platform via the 4G / 5G network; Cloud analytics: After receiving data, the cloud platform performs storage, analysis, and visualization processing, and compares it with preset thresholds to determine whether there are any anomalies. Application demonstration and control: Under normal conditions, the water temperature value and curve are displayed in real time on the PC / APP, and historical data is recorded; under abnormal conditions, multi-level alarms are triggered immediately, and notifications are pushed to maintenance personnel. At the same time, control signals can be automatically sent to the heating furnace PLC to adjust the heating status or activate the protection mechanism.

Images