Device and process for full-automatic pipe scraping of air cooler

Abstract

The invention relates to the technical field of air cooler finned tube manufacturing, in particular to a device and process for full-automatic tube scraping of an air cooler. The process comprises the following steps of: penetrating a finned tube through a tube plate and fixing the finned tube on the tube plate; establishing a user coordinate system of the robot and the pipe panel; the actual position of the pipe opening is recognized through image capturing equipment, recognized information is transmitted to an upper computer, the upper computer calculates the deviation between the actual position and the theoretical position of the pipe opening, and the deviation value is converted into a coordinate value of robot movement; a pipe opening is recognized through image capturing equipment, then a pipe scraping machine head is made to directly face the pipe opening, a cutter head on the pipe scraping machine head is made to rotate clockwise, when a blade arranged on the pipe scraping machine head starts to make contact with the pipe opening, pipe scraping operation starts, and when the robot moves forwards till the extension length of the pipe opening is remaining by 8 mm, the robot stops moving. The technical problems that in the prior art, manual pipe scraping is poor in pipe scraping quality, low in pipe scraping efficiency and large in damage to physical health of operators are effectively solved.

Description

Technical Field

[0001] This invention relates to the field of air cooler finned tube manufacturing technology, and in particular to a device and process for fully automated tube scraping in air coolers. Background Technology

[0002] An air cooler (referred to as "air cooler") is generally composed of main parts such as tube bundle, tube box, fan, louvers and frame. Among them, the tube bundle is the core component of the air cooler, which is composed of many finned tubes to increase the heat exchange area. The fan is used to provide forced ventilation, accelerate air flow and improve heat exchange efficiency.

[0003] During the manufacturing process of air coolers, finned tubes used for conveying the medium are inserted into small holes on the front and rear tube sheets of the air cooler. According to design requirements, the distance the finned tubes extend beyond the tube sheet surface is typically 5-8 mm. However, due to unavoidable assembly errors during manufacturing, the actual total length of the finned tubes is approximately 20-25 mm longer than the vertical distance between the front and rear tube sheet surfaces. After insertion, the distance between the front tube sheet and the extended finned tubes is adjusted to meet design requirements, and then tack-welded using tungsten inert gas (TIG) welding. This fixed surface on the finned tube is commonly referred to as the "fixed surface." The extended finned tubes on the rear tube sheet typically exceed the design distance by 5-10 mm. The end face of the finned tube extending beyond the rear tube sheet is commonly referred to as the "scraped surface," and it needs to be scraped off before welding. Currently, this is usually done manually using a pneumatic scraper to sequentially scrape the tubes to ensure the finned tube length meets design requirements.

[0004] While manually operating a pneumatic tube scraper can ensure the finned tube length meets design requirements, the scraper's rotation speed, feed rate, and distance are all manually controlled. This manual intervention significantly impacts the scraping quality and the remaining length at each end, resulting in poor consistency of the scraped finned tubes. Furthermore, close-range manual operation without adequate safety measures increases the risk of burns from flying metal filings. The large number of finned tubes and prolonged operation also lead to high labor intensity, reduced scraping efficiency, and noise levels exceeding 120 decibels, which can damage the operator's hearing over time. Summary of the Invention

[0005] This invention provides a device and process for fully automated tube scraping of air coolers, in order to solve the technical problems of poor tube scraping quality, low scraping efficiency, and significant damage to the health of operators caused by manual tube scraping in the prior art.

[0006] To solve the above problems, the device for fully automated tube scraping of air coolers provided by the present invention adopts the following technical solution: A device for fully automated tube scraping in an air cooler, comprising: The workstation chassis has a robot and a host computer connected to the robot via signals mounted on its top surface. The robot includes a rotating base mounted on the working chassis, on which mechanical joints are mounted, and adjacent mechanical joints are connected by servo motors to form a robotic arm, the end of which opposite the rotating base has an end shaft; The tube scraping head is mounted on the end shaft. The tube scraping head includes a housing with a motor inside. One end of the housing is equipped with a scraper assembly for scraping the tube. An image capture device is provided on one side of the scraper assembly for identifying the position of the tube opening. The host computer is connected to the servo motor, the chassis, and the image capture device via signals.

[0007] The beneficial effects of the fully automated tube scraping device for air coolers provided by this invention are as follows: By setting a motor inside the scraping head to provide power and torque for the rotation of the scraper assembly, the rotation speed and torque of the scraper can be effectively quantified and controlled, and the noise generated during the scraping process can be reduced, optimizing the working environment and protecting the hearing health of the workers; by controlling the feed speed and feed distance of the scraper assembly by a robot, the stability of the feed speed control can be ensured, and the feed distance of the scraper assembly can be accurately calculated according to the extension length of different tube openings, so as to ensure that the extension length of each tube opening is consistent after scraping; by executing all scraping commands by a robot, no close-range operation or observation by the workers is required. The robot can work continuously and stably, unaffected by fatigue or emotional factors, which can not only greatly reduce the labor intensity of the workers and improve the efficiency of scraping, but also effectively prevent people from being burned by flying iron filings, further protecting the health of the workers.

[0008] Through the above-mentioned design, the present invention effectively solves the technical problems of poor scraping quality, low scraping efficiency, and significant damage to the health of operators caused by manual scraping in the prior art.

[0009] Furthermore, a robot mounting base is installed on the workstation chassis, and the robot is mounted on the robot mounting base.

[0010] Furthermore, a robot control cabinet is installed on the workstation chassis, the servo motor and the chassis are signal-connected to the robot control cabinet, and the robot control cabinet is signal-connected to the host computer.

[0011] Furthermore, the robot is a six-axis robot.

[0012] Beneficial effects: The six-axis robot has six rotational axes, each of which can achieve multiple degrees of freedom of movement, providing excellent flexibility and enabling high-precision positioning and accurate motion control, thereby improving tube scraping efficiency and quality.

[0013] Furthermore, the scraper assembly includes a blade mounting base mounted on the chassis, on which a blade is mounted and on which blades are disposed.

[0014] Furthermore, the blade is an alloy blade.

[0015] Beneficial effects: Alloy blades have high hardness, high precision, and good wear resistance and stability. They are not easily worn during long-term use and can maintain a sharp cutting edge, thus ensuring scraping efficiency and quality. Their high precision ensures stability and consistency during the scraping process, resulting in more accurate scraping effects. In addition, alloy blades have a long service life, reducing the frequency of blade replacement during scraping, thereby reducing production costs and downtime.

[0016] Furthermore, the image capturing device is a 2D camera.

[0017] Beneficial effects: The 2D camera has high resolution and advanced image processing algorithms, which can achieve high-precision and high-speed measurement and positioning of the pipe opening, and can capture and transmit image data in real time, effectively improving the efficiency of pipe opening positioning.

[0018] Furthermore, the chassis is mounted on the end shaft via a flange.

[0019] Beneficial effects: Connecting the chassis to the end shaft via a flange simplifies installation and disassembly, facilitates chassis maintenance and replacement, and the flange connection effectively transmits torque from the end shaft, ensuring synchronous movement between the chassis and the end shaft, thereby guaranteeing the accuracy and quality of the scraping process.

[0020] To solve the above problems, the process for fully automated tube scraping in air coolers provided by this invention adopts the following technical solution: A process for fully automated tube scraping in air coolers, implemented using the aforementioned device for fully automated tube scraping in air coolers, comprises the following steps: S1: Pass the finned tubes through the tube sheets of the front and rear tube boxes and fix them to the tube sheets. Then hoist the air cooler to the front of the workstation chassis so that the tube sheet surface is located in front of the workstation chassis and within the effective working range. S2: The mobile robot makes the scraper head on its end axis contact the lower left, lower right and upper right corners of the tube sheet through the calibration rod to establish the user coordinate system between the robot and the tube sheet surface; S3: Open the host computer and set the pipe opening calibration parameters so that the image capture device on the pipe scraper head is directly in front of the pipe opening. The image capture device identifies the actual position of the pipe opening and transmits the identified information to the host computer. The host computer calculates the deviation between the actual position and the theoretical position of the pipe opening and converts the deviation value into the coordinate value for robot movement, so that the robot moves to the actual position of the pipe opening to scrape the pipe. S4: The host computer controls the robot to move to the pipe opening, so that the image capture device is facing the pipe opening to identify it. Then the robot continues to move, so that the scraping head is facing the pipe opening. After a 2-second delay, the host computer starts the motor inside the scraping head, so that the cutter head on the scraping head rotates clockwise. At this time, the robot moves along the axis of the pipe opening to the pipe plate surface. When the blade set on the scraping head begins to contact the pipe opening, the scraping operation begins. When the robot moves forward until the remaining length of the pipe opening is 8mm, it stops moving.

[0021] The beneficial effects of the fully automated tube scraping process for air coolers provided by this invention are as follows: By setting a motor inside the tube scraping head to provide power for the rotation of the scraper assembly, the rotational speed and torque of the scraper can be effectively quantified and controlled; by controlling the scraper's feed speed and feed distance with a robot, the stability of the feed speed control can be ensured, and the feed distance of the scraper can be accurately calculated according to the extension length of different tube openings, so as to ensure that the extension length of each tube opening is consistent after scraping; by executing all tube scraping commands by a robot, no close-range operation or observation by personnel is required, and the robot can work continuously and stably, unaffected by factors such as fatigue and emotions, which can not only greatly reduce the labor intensity of personnel and improve the efficiency of tube scraping, but also effectively prevent personnel from being burned by flying iron filings; in addition, by connecting two adjacent mechanical joints of the robot with servo motors, the noise generated by tube scraping can be reduced while ensuring the robot's driving power, greatly optimizing the working environment of tube scraping and protecting the health of personnel.

[0022] Through the above-mentioned design, the present invention effectively solves the technical problems of poor scraping quality, low scraping efficiency, and significant damage to the health of operators caused by manual scraping in the prior art.

[0023] Furthermore, in step S1, after the finned tube is inserted, the length of the finned tube extending out of the tube sheet on the front tube box is 8mm, and the finned tube is welded to the tube sheet by tungsten inert gas welding.

[0024] The beneficial effects of the fully automated tube scraping device and process for air coolers provided by this invention are as follows: By setting up a robot to drive the movement of the tube scraping head, and setting a motor inside the tube scraping head, a stable and sufficient power can be provided for the rotation of the scraper assembly, achieving precise control of the scraper speed and torque, and reducing the noise generated during the tube scraping process, thus optimizing the working environment of tube scraping; by controlling the robot's movement through a host computer, the feed speed and feed distance of the scraper can be controlled, ensuring a stable feed speed, and accurately calculating the scraper feed distance according to the extension length of different tube openings, so as to ensure the consistency of the remaining extension length and the consistency of the tube scraping quality after scraping each tube opening; in addition, the robot can continuously and stably perform tube scraping work, and is not affected by fatigue or emotional factors, which can greatly reduce the labor intensity of workers, improve tube scraping efficiency, and effectively prevent the occurrence of burns to workers caused by flying iron filings during tube scraping, thereby ensuring the health of operators.

[0025] Through the above-mentioned design, the present invention effectively solves the technical problems of poor scraping quality, low scraping efficiency, and significant damage to the health of operators caused by manual scraping in the prior art. Attached Figure Description

[0026] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent upon reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of the invention are illustrated by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein: Figure 1 This is a schematic diagram of the structure of the device for fully automated scraping of air coolers provided by the present invention; Figure 2 This is a schematic diagram of the scraping head in the fully automated scraping device for air coolers provided by the present invention; Figure 3 This is a schematic diagram of the tube sheet structure in this invention; Figure 4 This is a schematic diagram of the installation of finned tubes on a tube sheet in this invention; Figure 5 This is a flowchart of the process for fully automated tube scraping in air coolers provided by the present invention.

[0027] Explanation of reference numerals in the attached figures: 1. Workstation chassis; 2. Rotary base; 3. Mechanical joint; 4. Servo motor; 5. Scraper head; 6. Chassis; 7. 2D camera; 8. Host computer; 9. Robot mounting base; 10. Robot control cabinet; 11. Cutter head mounting base; 12. Cutter head; 13. Alloy blade; 14. Flange; 15. Tube sheet body; 16. Small hole; 17. Finned tube. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Those skilled in the art should understand that the embodiments described below are only some, not all, of the embodiments disclosed. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0029] It should be noted that the main concept of this invention is as follows: By installing a robot and a host computer 8 on the workstation chassis 1, and connecting the robot to the host computer 8 via signals, a scraping head 5 with a scraper assembly and an image capture device is installed on the robot's end shaft. A servo motor 4 connects two adjacent mechanical joints 3 in the robot. During the scraping process, the robot can provide power for the movement of the scraping head 5 under the control of the host computer 8, with low noise, thus optimizing the scraping working environment. By connecting the image capture device to the host computer 8 via signals, the position information of the pipe opening can be collected in real time and transmitted to the host computer 8. The host computer 8 controls the robot's movement based on the received information, thereby achieving precise control of the scraper's feed speed and feed distance, ensuring the consistency of the remaining protrusion length and scraping quality after scraping each pipe opening. During the scraping process, the host computer 8 issues control commands, which are then executed by the robot, eliminating the need for close-range operation or observation by personnel. This not only protects the health of personnel and reduces their labor intensity but also improves scraping efficiency.

[0030] After introducing the basic principles of the present invention, various non-limiting embodiments of the present invention are described in detail below. Any number of elements in the accompanying drawings is for illustrative purposes only and not for limitation, and any naming is for distinction only and has no limiting meaning.

[0031] An air cooler is a heat exchanger that uses air as a coolant to cool a hot fluid. It mainly consists of a tube bundle, a fan, louvers, and a frame. The tube bundle is the core component of the air cooler and serves as the central part for heat exchange. It comprises finned tubes, a tube box, and a frame, and can be completely assembled and disassembled on the air cooler frame. The fan is a key component for enhancing external heat transfer and also forces airflow. The louvers not only regulate airflow but also protect the finned tubes.

[0032] Finned tubes, as a major component of tube bundles, increase the heat exchange area and improve heat exchange efficiency through their finned structure. The hot fluid inside the finned tube exchanges heat with the outside air through the tube wall and fins, thereby achieving a cooling effect.

[0033] During the manufacturing process of the air cooler, finned tubes are inserted from the center of the air cooler into small holes in the front and rear tube sheet. Due to unavoidable assembly errors during manufacturing, the actual total length of the finned tubes is approximately 20-25mm longer than the vertical distance between the two tube sheet surfaces. To meet design requirements, after the tubes are inserted, the distance between the finned tubes and the front tube sheet is adjusted to meet the design requirements, and then tack welded using tungsten inert gas welding. The distance of the finned tubes extending from the rear tube sheet typically exceeds the design distance by 5-10mm, and the excess finned tubes need to be scraped off before welding.

[0034] Currently, the finned tubes are typically scraped manually using a pneumatic scraper to ensure the length meets design requirements. While manual operation of the pneumatic scraper can achieve the desired length, the scraper's rotation speed, feed rate, and feed distance are all manually controlled during the scraping process. This significantly impacts the scraping quality and the remaining length at each end, resulting in poor consistency in the produced finned tubes. Furthermore, the lack of effective safety measures when operating the scraper at close range makes operators highly susceptible to burns from flying metal shavings. Additionally, the large number of finned tubes and prolonged operation lead to high labor intensity, reduced scraping efficiency, and noise levels exceeding 120 decibels during pneumatic scraping, which can damage operators' hearing over time.

[0035] Based on this, the present invention provides a device and process for fully automated tube scraping of air coolers, in order to solve the technical problems of poor tube scraping quality, low tube scraping efficiency, and great harm to the health of operators caused by manual tube scraping in the prior art.

[0036] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0037] Embodiment 1 of the device for fully automated tube scraping of air coolers provided by the present invention: like Figures 1 to 4 As shown, the device for fully automated tube scraping of air coolers includes a workstation chassis 1, on which a robot and a host computer 8 connected to the robot by signals are mounted, and a tube scraping head 5 is mounted on the robot.

[0038] About the robot. The robot is a six-axis robot. As the name suggests, a six-axis robot is an industrial robot with six rotating axes (or mechanical joints 3). These axes allow the robot to move and rotate freely in three-dimensional space, enabling it to perform various complex tasks and be applied in various manufacturing and processing fields. A six-axis robot mainly consists of an actuator, a drive system, and an automatic control system. The actuator is the main part of the robot, including a rotating base 2, a robotic arm, and an end effector. The robotic arm is composed of six mechanical joints 3 connected sequentially. The drive system includes servo motors 4 connecting adjacent mechanical joints 3. The drive system provides power to the robot, enabling it to move along a predetermined trajectory and speed. The automatic control system is the robot's brain, responsible for receiving instructions, processing information, and controlling the robot's movement. The automatic control system is connected to the servo motors 4 and a host computer 8 to receive control instructions from the host computer 8 and control the servo motors 4 according to the received instructions.

[0039] Specifically, the end effector is a scraper head 5 mounted on the end shaft, which is located at the end of the robotic arm away from the rotating base 2.

[0040] Specifically, a robot mounting base 9 is installed on the workstation chassis 1, a six-axis robot is installed on the robot mounting base 9, and the drive system includes a robot control cabinet 10 installed on the workstation chassis 1. The servo motor 4 is connected to the robot control cabinet 10 by signal, and the robot control cabinet 10 is connected to the automatic control system by signal.

[0041] The working principle of the six-axis robot is as follows: Under the control of the host computer 8, the robot automatically adjusts the relative position of the actuators according to the required sequence, trajectory, speed and time. The robot control cabinet 10 controls the servo motor 4 to move. The automatic control system sends instructions to the robot control cabinet 10 according to the preset program or the instructions of the host computer 8, so that the robot moves according to the specified trajectory and speed.

[0042] Six-axis robots offer advantages such as high degrees of freedom, high precision, high efficiency, and good safety. Firstly, with six rotary axes, they can adapt to various trajectories and angles, possessing extremely high degrees of freedom. Secondly, they employ advanced control systems, enabling high-precision operation to meet the needs of various precision manufacturing processes. Thirdly, they can work continuously and stably, unaffected by fatigue or emotional factors, significantly improving production efficiency. Finally, six-axis robots can replace humans in performing dangerous or harmful tasks, thus ensuring human safety.

[0043] Regarding the tube scraper head 5: The tube scraper head 5 is mounted on the end shaft and includes a housing 6. The housing 6 houses a motor. One end of the housing 6 is equipped with a scraper assembly for scraping tubes. An image capture device is provided on one side of the scraper assembly for identifying the position of the tube opening. A calibration rod (not shown in the figure) is provided on the housing 6 around the scraper assembly.

[0044] The scraper assembly includes a cutter head mounting base 11 mounted on the chassis 6, a cutter head 12 mounted on the cutter head mounting base 11, and a blade on the cutter head 12. The chassis 6 is mounted on the end shaft via a flange 14 and is signal-connected to the robot control cabinet 10.

[0045] Specifically, the blade is an alloy blade 13, and the image capture device is a 2D camera 7.

[0046] Regarding the tube sheet: The tube sheet includes a tube sheet body 15, on which multiple rows of small holes 16 are formed, each row including multiple small holes 16 spaced apart.

[0047] The working principle of the device for fully automated tube scraping in air coolers provided by this invention is as follows: First, pass the finned tubes 17 through the small holes 16 opened on the tube sheets of the front and rear tube boxes respectively, adjust the distance of the finned tubes 17 extending out of the front tube box to 8mm, and then spot weld them to the tube sheet using tungsten inert gas welding. Then, hoist the air cooler with the spot welded "fixed surface" to the front of the workstation chassis 1, so that the distance between the tube sheet surface and the front of the workstation chassis 1 is within the effective working range of 1.2-1.5m. Then, the six-axis robot installed on the mobile workstation chassis 1 makes the scraping head 5 located at its end axis contact the lower left corner, lower right corner and upper right corner of the tube sheet through the calibration rod. The user coordinate system between the six-axis robot and the tube sheet surface is established by the "three-point method" calculation. The six-axis robot will then perform scraping work in the user coordinate system. Next, open the scraping software on the upper computer 8 working interface, set the tube opening calibration parameters according to the tube opening specifications of the finned tube 17, set the inner diameter of the tube opening to 28mm, the allowable diameter deviation range to ±0.4mm, the minimum distance between tube openings to 37mm, and the tube opening protrusion distance to 8mm. Then, select any two tube openings on the tube plate in the drawing on the software interface for tube opening calibration. Move the six-axis robot to the two tube openings respectively, so that the 2D camera 7 is placed directly in front of the tube opening. The 2D camera 7 accurately identifies the actual position of each tube opening, and the scraping software calculates the deviation between the actual position of the tube opening and the theoretical position in the CAD drawing. Then, the deviation value is converted into the coordinate value of the six-axis robot movement, so that the six-axis robot can accurately move to the actual position of the tube opening for scraping. Finally, select any pipe opening on the tube sheet in the drawing on the scraping software interface of the host computer 8, and start the robot's automatic mode. The six-axis robot, carrying the scraping head 5 on the end axis, moves to the position where the 2D camera 7 is facing the pipe opening. After the 2D camera 7 identifies the pipe opening, the six-axis robot continues to move so that the scraping head 5 is facing the pipe opening. After a 2-second delay, start the motor inside the scraping head 5 to make the cutter head 12 rotate clockwise. At this time, the robot moves along the pipe opening axis towards the tube sheet surface at a speed of 0.5-2 mm / s. When the alloy blade 13 on the scraping machine begins to contact the pipe opening, the scraping operation begins. When the six-axis robot moves forward and the remaining pipe opening protrudes by 8 mm, it stops moving and controls the cutter head 12 to gradually stop rotating, and the scraping is completed. If the rotation center of the cutter head 12 is not concentric with the finned tube 17, the relative values ​​of X and Y in the visual parameters of the tube scraping software can be adjusted to meet the concentricity requirement. If the tube opening quality and remaining length do not meet the requirements, the motor speed can be adjusted through the tube scraping software. When performing tube scraping operations, after the parameters are adjusted and stabilized, all tube openings of the tube sheet in the drawing on the tube scraping software interface can be selected to start the automatic mode. The six-axis robot will carry the tube scraping head 5 to automatically scrape all tube openings in sequence.

[0048] Embodiment 2 of the device for fully automated tube scraping of air coolers provided by the present invention: Its main difference from Example 1 is: In Example 1, the image capture device is a 2D camera.

[0049] In this embodiment, the image capture device is a camera.

[0050] Embodiment 3 of the device for fully automated tube scraping of air coolers provided by the present invention: Its main difference from Example 1 is: In Example 1, the blade is an alloy blade.

[0051] In this embodiment, the blade is a ceramic blade.

[0052] An embodiment of the process for fully automated tube scraping in air coolers provided by this invention: like Figure 5 As shown, the process for fully automated tube scraping in air coolers includes the following steps: S1: Pass the finned tubes through the tube sheets of the front and rear tube boxes and fix them to the tube sheets. Then hoist the air cooler to the front of the workstation chassis so that the tube sheet surface is located in front of the workstation chassis and within the effective working range. S2: The mobile robot makes the scraper head on its end axis contact the lower left, lower right and upper right corners of the tube sheet through the calibration rod to establish the user coordinate system between the robot and the tube sheet surface; S3: Open the host computer and set the pipe mouth calibration parameters so that the image capture device on the pipe scraper head is directly in front of the pipe mouth. The image capture device identifies the actual position of the pipe mouth and transmits the identified information to the host computer. The host computer calculates the deviation between the actual position and the theoretical position of the pipe mouth and converts the deviation value into the coordinate value for robot movement, so that the robot moves to the actual position of the pipe mouth to scrape the pipe. S4: The host computer controls the robot to move to the pipe opening, so that the image capture device is facing the pipe opening to identify it. Then the robot continues to move, so that the scraping head is facing the pipe opening. After a 2-second delay, the host computer starts the motor inside the scraping head, so that the cutter head on the scraping head rotates clockwise. At this time, the robot moves along the axis of the pipe opening to the pipe plate surface. When the blade set on the scraping head begins to contact the pipe opening, the scraping operation begins. When the robot moves forward until the remaining length of the pipe opening is 8mm, it stops moving.

[0053] For step S1, during the tube insertion, the finned tube is adjusted so that the distance from its extension to the front tube box is 8mm, and it is spot-welded to the tube sheet using tungsten inert gas welding. Then, the spot-welded "fixed surface" air cooler is hoisted to the front of the workstation chassis, so that the distance between the tube sheet surface and the front of the workstation chassis is within the effective working range of 1.2-1.5m.

[0054] For step S3, first open the scraping software on the host computer interface, set the tube opening calibration parameters according to the tube opening specifications of the finned tube, set the inner diameter of the tube opening to 28mm, the allowable diameter deviation range to ±0.4mm, the minimum distance between tube openings to 37mm, and the tube opening protrusion distance to 8mm, etc. Then, select any two tube openings on the tube plate in the drawing on the scraping software interface for tube opening calibration, move the robot to the two tube openings respectively, place the image capture device directly in front of the tube opening, accurately identify the actual position of each tube opening through the image capture device, and calculate the deviation between the actual position of the tube opening and the theoretical position in the CAD drawing through the scraping software. Then, convert the deviation value into the coordinate value of the robot movement, so that the robot can accurately move to the actual position of the tube opening for scraping.

[0055] If the rotation center of the cutter head is not concentric with the finned tube, the relative values ​​of X and Y in the visual parameters of the tube scraping software can be adjusted to meet the concentricity requirement. If the tube opening quality and remaining length do not meet the requirements, the motor speed, feed speed, feed distance and other parameters can be adjusted through the tube scraping software. The specific parameter ranges are shown in Table 1. When performing tube scraping operations, after the parameters are adjusted and stabilized, all tube openings in the tube sheet in the drawing on the software interface can be selected to start the automatic mode. The robot will carry the tube scraping head to automatically scrape all tube openings in sequence.

[0056] Table 1

[0057] Based on the above description in this specification, those skilled in the art will also understand that the following terms, such as "upper," "lower," "front," "rear," "left," "right," "width," "horizontal," "top," "bottom," "inner," and "outer," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings of this specification. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description, and do not explicitly or implicitly suggest that the device or element involved must have the specific orientation, or be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms should not be understood or interpreted as limitations on the present invention.

[0058] In addition, in the description of this specification, "multiple" means at least two, such as two, three or more, etc., unless otherwise expressly and specifically defined.

Claims

1. A device for fully automated tube scraping in air coolers, characterized in that, include: The workstation chassis has a robot and a host computer connected to the robot via signals mounted on its top surface. The robot includes a rotating base mounted on the working chassis, on which mechanical joints are mounted, and adjacent mechanical joints are connected by servo motors to form a robotic arm, the end of which opposite the rotating base has an end shaft; The tube scraping head is mounted on the end shaft. The tube scraping head includes a housing with a motor inside. One end of the housing is equipped with a scraper assembly for scraping the tube. An image capture device is provided on one side of the scraper assembly for identifying the position of the tube opening. The host computer is connected to the servo motor, the chassis, and the image capture device via signals.

2. The device for fully automated tube scraping of an air cooler according to claim 1, characterized in that, The workstation chassis is equipped with a robot mounting base, and the robot is mounted on the robot mounting base.

3. The device for fully automated tube scraping of an air cooler according to claim 2, characterized in that, A robot control cabinet is installed on the workstation chassis. The servo motor and the chassis are connected to the robot control cabinet via signal, and the robot control cabinet is connected to the host computer via signal.

4. The apparatus for fully automated tube scraping of an air cooler according to any one of claims 1 to 3, characterized in that, The robot is a six-axis robot.

5. The apparatus for fully automated tube scraping of an air cooler according to any one of claims 1 to 3, characterized in that, The scraper assembly includes a blade mounting base mounted on the chassis, on which a blade is mounted and on which blades are disposed.

6. The device for fully automated tube scraping of an air cooler according to claim 5, characterized in that, The blade is an alloy blade.

7. The apparatus for fully automated tube scraping of an air cooler according to any one of claims 1 to 3, characterized in that, The image capture device is a 2D camera.

8. The apparatus for fully automated tube scraping of an air cooler according to any one of claims 1 to 3, characterized in that, The chassis is mounted on the end shaft via a flange.

9. A process for fully automated tube scraping in air coolers, characterized in that, It is implemented using the device for fully automatic tube scraping of air coolers as described in any one of claims 1 to 8, and the specific steps are as follows: S1: Pass the finned tubes through the tube sheets of the front and rear tube boxes and fix them to the tube sheets. Then hoist the air cooler to the front of the workstation chassis so that the tube sheet surface is located in front of the workstation chassis and within the effective working range. S2: The mobile robot makes the scraper head on its end axis contact the lower left, lower right and upper right corners of the tube sheet through the calibration rod to establish the user coordinate system between the robot and the tube sheet surface; S3: Open the host computer and set the pipe mouth calibration parameters so that the image capture device on the pipe scraper head is directly in front of the pipe mouth. The image capture device identifies the actual position of the pipe mouth and transmits the identified information to the host computer. The host computer calculates the deviation between the actual position and the theoretical position of the pipe mouth and converts the deviation value into the coordinate value for robot movement, so that the robot moves to the actual position of the pipe mouth to scrape the pipe. S4: The host computer controls the robot to move to the pipe opening, so that the image capture device is facing the pipe opening to identify it. Then the robot continues to move, so that the scraping head is facing the pipe opening. After a 2-second delay, the host computer starts the motor inside the scraping head, so that the cutter head on the scraping head rotates clockwise. At this time, the robot moves along the axis of the pipe opening to the pipe plate surface. When the blade set on the scraping head begins to contact the pipe opening, the scraping operation begins. When the robot moves forward until the remaining length of the pipe opening is 8mm, it stops moving.

10. The process for fully automated tube scraping in air coolers according to claim 9, characterized in that, In step S1, after the finned tube is installed, the length of the finned tube extending out of the tube sheet on the front tube box is 8mm, and the finned tube is welded to the tube sheet by tungsten inert gas welding.

Images