Large heat exchanger tube core guiding, installing and conveying mechanism, control method and system

Abstract

The application provides a large heat exchanger tube core guiding installation and conveying mechanism, a control method and a system, which comprise a warehouse storage device and a tube core conveying device, the warehouse storage device is provided with an outlet, the outlet position is provided with a discharging device, the discharging device is used for controlling the discharging amount of the outlet; the tube core conveying device is arranged at the bottom of the warehouse discharging device and directly below the outlet, the tube core conveying device comprises a bottom truss, a rotating support assembly arranged on the bottom truss, a guiding assembly, a traction assembly and a hydraulic driving assembly, the bottom truss is directly below the warehouse storage device, the rotating support assembly is arranged on the bottom truss and directly below the outlet, and the two ends of the bottom truss are correspondingly provided with the traction assembly and the hydraulic driving assembly; a pressure sensor and a controller, the pressure sensor is arranged on the rotating support assembly; wherein the pressure sensor, the traction assembly and the hydraulic driving assembly are electrically connected with the controller.

Description

Technical Field

[0001] This invention belongs to the field of heat exchanger tube replacement technology, and specifically relates to a large heat exchanger core guiding installation and conveying mechanism, control method and system. Background Technology

[0002] Heat exchange tubes are an important component of shell-and-tube heat exchangers, possessing high thermal conductivity and good isothermal properties, enabling rapid heat transfer from one point to another. The heat exchange tubes are fixed inside the heat exchanger by baffles.

[0003] Traditional tube insertion is done manually. Specifically, baffles have multiple insertion holes spaced at intervals, and workers insert the heat exchange tubes sequentially through these holes into multiple baffles. Since heat exchange tubes are typically 3-6 meters long, and large shell-and-tube heat exchangers can reach 9 meters in length, multiple workers are needed to lift the tubes and insert them into the baffles. Furthermore, because heat exchangers can be up to 3 meters high, operators often need lifting devices to insert the tubes manually. A single heat exchanger often requires hundreds or thousands of heat exchange tubes. Additionally, for large heat exchangers, inserting a certain number of tubes can cause the baffles to deform due to the increased weight, making subsequent tube insertion more difficult. In summary, traditional manual tube insertion is extremely labor-intensive, costly, and inefficient.

[0004] It is evident that designing a device capable of automatic tube loading and insertion that can move horizontally up and down is an important problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The present invention provides a large heat exchanger core guiding, installation and conveying mechanism to at least solve the above-mentioned technical problems;

[0006] To address the aforementioned problems, a first aspect of the present invention provides a large heat exchanger core guiding, installation, and conveying mechanism. The conveying mechanism includes: a storage device for temporarily storing a plurality of heat exchanger tubes, the storage device having an outlet, and a discharge device positioned at the outlet for controlling the discharge quantity; a core conveying device disposed at the bottom of the storage device and directly below the outlet, the core conveying device including: a bottom truss, a rotating support assembly disposed on the bottom truss, a guiding assembly, a traction assembly, and a hydraulic drive assembly, the bottom truss being directly below the storage device, the rotating support assembly being disposed on the bottom truss and directly below the outlet, and the traction assembly and the hydraulic drive assembly being correspondingly disposed at both ends of the bottom truss; a pressure sensor and a controller, the pressure sensor being disposed on the rotating support assembly; wherein the pressure sensor, the traction assembly, and the hydraulic drive assembly are all electrically connected to the controller.

[0007] In the first aspect, the discharge device includes a first motor, a coupling, and four rotating wheels. The output end of the first motor is connected to the four rotating wheels via the coupling. The four rotating wheels consist of a disc-shaped wheel body and a plurality of clamping portions spaced circumferentially around the wheel body. Each clamping portion is capable of clamping one heat exchange tube, and each clamping portion is positioned at the outlet position as the wheel body rotates. The outlet includes a horizontal portion and an inclined portion. The horizontal portion is used to place the single heat exchange tube, and the rotation direction of the wheel body is from the horizontal portion to the inclined portion. The inclined portion guides the direction of the outlet to the rotating support assembly.

[0008] In the first aspect, the traction assembly includes two pairs of drive rollers, which are opposite each other and set at a 60-degree angle to the horizontal. Each drive roller includes: a base; a servo motor mounted on the base, the output end of the servo motor being coaxially connected to a synchronous pulley, and the output end of the synchronous pulley being coaxially connected to a non-circular roller; wherein a heat exchange tube can be accommodated between a pair of non-circular rollers.

[0009] In the first aspect, the irregular roller has a pair of protruding shaft ends at both ends, each shaft end being provided with a movable slider that can slide along the length direction of the shaft end.

[0010] In the first aspect, the rotating support assembly includes: a plurality of sets of rollers, wherein the plurality of sets of rollers are sequentially arranged on the bottom truss.

[0011] In the first aspect, the hydraulic drive assembly includes a push hydraulic cylinder and a push head, the push head being disposed at the output end of the push hydraulic cylinder.

[0012] Secondly, the present invention provides an installation control method for a large heat exchanger core guiding, installation, and conveying mechanism. The large heat exchanger core guiding, installation, and conveying mechanism includes: a storage device, a core conveying device, a pressure sensor, and a controller. The storage device stores several heat exchanger tubes. The core conveying device includes a bottom truss, a rotating support assembly mounted on the bottom truss, a guiding assembly, a traction assembly, and a hydraulic drive assembly. The pressure sensor is mounted on the rotating support assembly. The control method includes: firstly acquiring a pressure value signal detected by the pressure sensor through the control assembly, and determining whether the pressure value is a preset pressure threshold based on the pressure value signal; if not, the controller controls the discharge device to lower one heat exchanger tube to the rotating support assembly; secondly acquiring the pressure value signal detected by the pressure sensor through the control assembly, and determining whether the pressure value is a preset pressure threshold based on the pressure value signal; if so, the control assembly controls the hydraulic drive assembly to perform a driving action, and then controls the traction assembly to perform a traction action.

[0013] In the second aspect, the hydraulic drive assembly includes a push hydraulic cylinder and a push head, the push head being disposed at the output end of the push hydraulic cylinder, and the control assembly controlling the hydraulic drive assembly to drive includes: the control assembly controlling the push hydraulic cylinder to hydraulically drive, so that the push head undergoes a corresponding extension or retraction displacement.

[0014] In the second aspect, the discharge device includes: a first motor, a coupling, and four rotating wheels. The four rotating wheels consist of a disc-shaped wheel body and a plurality of clamping portions arranged circumferentially around the wheel body. Each clamping portion is capable of clamping one heat exchange tube. Each clamping portion is positioned at the outlet position as the wheel body rotates. The controller controls the discharge device to lower one heat exchange tube to the rotating support assembly by: the controller controlling the first motor to drive the four rotating wheels to rotate, so that one of the clamping portions clamps one heat exchange tube and pushes it towards the outlet position.

[0015] Thirdly, the present invention provides a large heat exchanger core guiding installation and conveying system, the system including any one of the large heat exchanger core guiding installation and conveying mechanisms described above.

[0016] Beneficial Effects: This invention proposes a large-scale heat exchanger core guiding, installation, and conveying mechanism. A fixed quantity of heat exchanger tubes is stored in a storage device and then output one by one. The core conveying device then transports the heat exchanger tubes one by one to the joint of the heat exchanger, replacing manual installation. Specifically, a preset number of heat exchanger tubes are stored in the storage device, and the storage quantity is controlled by the storage device. After exiting the outlet, the heat exchanger tubes are supported by a rotating support component of the core conveying device. A hydraulic drive component then pushes the heat exchanger tubes to a guiding component and a traction component. Finally, the traction component spirally pulls the heat exchanger tubes to the joint of the heat exchanger, achieving automatic installation of the heat exchanger tubes. This solves the technical problem of low efficiency in manual heat exchanger tube replacement, thereby improving the replacement efficiency of the heat exchanger tubes. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this specification or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of the large heat exchanger core guiding, installation and conveying mechanism according to Embodiment 1 of the present invention. Figure 1 ;

[0019] Figure 2 This is a front view of the traction component according to Embodiment 1 of the present invention;

[0020] Figure 3 This is a rear view of the traction component according to Embodiment 1 of the present invention;

[0021] Figure 4 This is a schematic diagram of the structure of the hydraulic drive assembly according to Embodiment 1 of the present invention;

[0022] Figure 5 This is a schematic diagram of the material storage device according to Embodiment 1 of the present invention;

[0023] Figure 6 This is a schematic diagram of the rotating support assembly according to Embodiment 1 of the present invention;

[0024] Figure 7 This is a schematic diagram of the structure of the guide component according to Embodiment 1 of the present invention;

[0025] Figure 8 The flowchart of the installation control method for the large heat exchanger core guiding and conveying mechanism in Embodiment 2 of the present invention is as follows: Figure 1

[0026] Figure 9The flowchart of the installation control method for the large heat exchanger core guiding and conveying mechanism in Embodiment 2 of the present invention is as follows: Figure 2 .

[0027] Numbering on the map:

[0028] 1. Traction assembly;

[0029] 2. Bottom truss;

[0030] 3. Guiding components;

[0031] 4. Rotating support assembly;

[0032] 5. Warehouse storage equipment;

[0033] 6. Discharge device;

[0034] 7. Rollers;

[0035] 8. Hydraulic drive components;

[0036] 9. Synchronizing pulley;

[0037] 10. Synchronous belt;

[0038] 11. Move the slider;

[0039] 12. Irregularly shaped rollers;

[0040] 13. Base;

[0041] 14. Servo motor;

[0042] 15. Motor support;

[0043] 16. Push the hydraulic cylinder;

[0044] 17. Push the head;

[0045] 18. Couplings;

[0046] 19. Four rotating wheels. Detailed Implementation

[0047] The technical solutions of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0048] Furthermore, in the embodiments of this specification, when a component is referred to as being "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. When a component is considered to be "set on" another component, it can be directly set on the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in the embodiments of this specification are for illustrative purposes only and are not intended to limit the invention.

[0049] Example 1:

[0050] like Figure 1-4 As shown, this embodiment provides a large heat exchanger core guiding installation and conveying mechanism. The conveying mechanism includes: a storage device 5 for temporarily storing several heat exchanger tubes, the storage device 5 having an outlet, and a discharge device 6 at the outlet position for controlling the discharge quantity at the outlet; a core conveying device, which is located at the bottom of the storage device 6 and directly below the outlet, the core conveying device including: a bottom truss 2, a rotating support assembly 4, a guide assembly 3, a traction assembly 1, and a hydraulic drive assembly 8, the bottom truss 2 being located directly below the storage device 5, the rotating support assembly 4 being located on the bottom truss 2 and directly below the outlet, and the traction assembly 1 and the hydraulic drive assembly 8 being correspondingly arranged at both ends of the bottom truss 2; a pressure sensor and a controller, the pressure sensor being located on the rotating support assembly 4; wherein, the pressure sensor, the traction assembly 1, and the hydraulic drive assembly 8 are all electrically connected to the controller.

[0051] Specifically, the large heat exchanger core guiding, installation, and conveying mechanism proposed in this embodiment stores a predetermined quantity of heat exchanger tubes in a storage device 5 and outputs them one by one. The core conveying device then transports the heat exchanger tubes one by one to the joint of the heat exchanger, replacing manual installation. Specifically, the storage device 5 stores a preset number of heat exchanger tubes, and the storage quantity is controlled by the storage device. After the heat exchanger tubes exit through the outlet, they are supported by the rotating support assembly 4 of the core conveying device. Then, a hydraulic drive assembly 8 pushes the heat exchanger tubes to the guiding assembly 3 and the traction assembly 1. Finally, the traction assembly 1 spirally pulls the heat exchanger tubes to the joint of the heat exchanger, achieving automatic installation of the heat exchanger tubes. This solves the technical problem of low efficiency in manual heat exchanger tube replacement, thereby improving the replacement efficiency of the heat exchanger tubes.

[0052] In some possible implementations, the discharge device 6 includes a first motor, a coupling 18, and four rotating wheels 19. The output end of the first motor is connected to the four rotating wheels 19 via the coupling 18. The four rotating wheels 19 consist of a disc-shaped wheel body and several clamping parts arranged circumferentially around the wheel body. Each clamping part can clamp a heat exchange tube. Each clamping part is located at the outlet position as the wheel body rotates. The outlet includes a horizontal part and an inclined part. The horizontal part is used to place a single heat exchange tube. The rotation direction of the wheel body is from the horizontal part to the inclined part. The inclined part guides the direction of the outlet to the rotating support assembly 4.

[0053] In the above embodiment 1, the output number of heat exchange tubes is controlled by setting four rotating wheels 19 in conjunction with a motor and a coupling 18. Specifically, the four rotating wheels 19 consist of a disc-shaped wheel body and clamping parts equidistantly arranged around the wheel body. The clamping parts can be C-shaped structures with their openings facing away from the wheel body. When the wheel body rotates for one unit of time, each clamping part automatically clamps the outer wall of a heat exchange tube. The unit of time is the time when the current clamping part clamps the current heat exchange tube and is driven by the motor to generate movement; that is, the time when the current clamping part clamps the heat exchange tube currently located in the horizontal part and pushes it to the inclined part.

[0054] In some possible implementations, the traction assembly 1 includes two pairs of drive rollers 7, which are opposite each other and set at a 60-degree angle to the horizontal. Each drive roller 7 includes: a base 13; a servo motor 14 mounted on the base 13, the output end of the servo motor 14 being coaxially connected to a synchronous wheel 9, and the output end of the synchronous wheel 9 being coaxially connected to a non-circular roller 12; wherein a heat exchange tube can be accommodated between a pair of non-circular rollers 12.

[0055] Specifically, the drive rollers 7, which are arranged in pairs at a 60-degree angle to the horizontal, clamp the middle tube core. The four servo motors 14 use the same speed so that the tangential force on the heat exchange tube is the same in magnitude but opposite in direction, thus achieving their own rotation. At the same time, the axial force will cause the tube core to move axially, thereby realizing the spiral advance of the tube core through the baffle plate. Each servo motor 14 is supported by a motor support 15.

[0056] In some possible implementations, the irregular roller 12 has a pair of protruding shaft ends at both ends, each shaft end is provided with a movable slider 11, which can slide along the length direction of the shaft end.

[0057] This is to accommodate heat exchange tubes of different diameters. A pair of adjustable sliding blocks 11 are used to adjust the diameter of the heat exchange tube to be clamped along the length of a pair of protruding shaft ends.

[0058] In some possible implementations, the rotating support assembly 4 includes several sets of rollers 7, which are sequentially arranged on the bottom truss 2.

[0059] Specifically, five sets of horizontally arranged rollers 7 without motors are set at equal intervals along the length of the bottom truss 2 to provide sliding support for the heat exchange tubes.

[0060] In some possible implementations, the hydraulic drive assembly 8 includes a driving hydraulic cylinder 16 and a driving head 17, the driving head 17 being disposed at the output end of the driving hydraulic cylinder 16.

[0061] In summary, the system mainly comprises four sets of roller mechanisms at a 60-degree angle to the horizontal, five sets of horizontally arranged roller mechanisms, five sets of horizontally arranged roller mechanisms without motors, and a tail-end pushing mechanism. The roller mechanisms at the 60-degree angle are installed at the head of the truss base 13. The four sets of roller mechanisms are installed in pairs, staggered. The two ends of the irregularly shaped rollers 12 are fixed in position by movable sliders 11. Adjusting the movable sliders 11 can change the spacing between the two sets of rollers 7 to accommodate different pipe diameters. One end of each roller 7 is connected to a servo motor 14 via a synchronous pulley 9 and a synchronous belt 10. The horizontal roller mechanisms are installed at the head of the warehouse unloading mechanism. The two ends of each roller 7 are fixed in position by movable sliders 11, and one end is connected to the servo motor 14 via a coupling 18. A pressure sensor is installed at the bottom of the movable slider 11. The tail-end pushing mechanism is fixed at the very end of the truss base 13. An elastic head is installed at the head of the hydraulic telescopic rod to facilitate tube pushing and protect the tube from scratches. The guide head mounting mechanism is fixed before the first set of horizontal roller mechanisms. The upper part stores the guide heads for easy replacement after use, while the lower part secures the guide heads to be installed each time, and the guide heads are installed in conjunction with the hydraulic push rod at the tail. The supporting truss serves as the base 13 of the entire device, and can be used to add conveying brackets and axial conveying mechanism sets for tubes of different lengths, thereby increasing the usability of the device. The warehouse discharge mechanism consists of a hopper body, pressure sensor, servo motor 14 and fixed support, four rotating wheels 19, coupling 18 and inclined slide. The pressure sensor is installed on the bottom surface inside the hopper body to detect pressure changes. The four rotating wheels 19 are symmetrically arranged at the bottom of the hopper body, connected and fixed to the servo motor 14 by the coupling 18. The inclined slide is fixedly installed at the bottom of the hopper body and connected to the discharge port.

[0062] Example 2:

[0063] This invention provides an installation control method for a large heat exchanger core guiding, installation, and conveying mechanism. The large heat exchanger core guiding, installation, and conveying mechanism includes: a storage device, a core conveying device, a pressure sensor, and a controller. The storage device stores several heat exchanger tubes. The core conveying device includes a bottom truss, a rotating support assembly mounted on the bottom truss, a guiding assembly, a traction assembly, and a hydraulic drive assembly. The pressure sensor is mounted on the rotating support assembly. The control method includes: firstly, the control assembly acquires a pressure value signal detected by the pressure sensor, and determines whether the pressure value is within a preset pressure threshold. If not, the controller controls the discharge device to lower a heat exchanger tube to the rotating support assembly. Secondly, the control assembly acquires a pressure value signal detected by the pressure sensor, and determines whether the pressure value is within a preset pressure threshold. If so, the control assembly controls the hydraulic drive assembly to perform a driving action, and then controls the traction assembly to perform a traction action.

[0064] Furthermore, the hydraulic drive assembly includes a push hydraulic cylinder and a push head, the push head being disposed at the output end of the push hydraulic cylinder. The control assembly controls the hydraulic drive assembly to generate drive by controlling the push hydraulic cylinder to generate hydraulic drive, so that the push head generates a corresponding extension and retraction displacement.

[0065] In another possible implementation, the discharge device includes: a first motor, a coupling, and four rotating wheels. The four rotating wheels consist of a disc-shaped wheel body and several clamping parts arranged circumferentially around the wheel body. Each clamping part can clamp a heat exchange tube. Each clamping part is positioned at the outlet position as the wheel body rotates. The controller controls the discharge device to lower a heat exchange tube to the rotating support assembly by: the controller controlling the first motor to drive the four rotating wheels to rotate, so that one of the clamping parts clamps a heat exchange tube and pushes it towards the outlet position.

[0066] Example 3:

[0067] This invention provides a large heat exchanger core guiding, installation and conveying system, the system including any of the above-mentioned large heat exchanger core guiding, installation and conveying mechanisms.

[0068] Since Embodiment 3 and Embodiment 1 are embodiments under the same inventive concept and have some identical structures, the substantially identical structures in Embodiment 3 and Embodiment 1 will not be described in detail. For the parts not described in detail, please refer to Embodiment 1.

[0069] Finally, it should be noted that the above embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the scope of the technology disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. All should be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0070] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A large heat exchanger tube core guide installation and transport mechanism, characterized in that, The conveying mechanism includes: A storage device for temporarily storing several heat exchange tubes, the storage device having an outlet, and a discharge device being provided at the outlet for controlling the discharge quantity from the outlet. A core conveying device is disposed at the bottom of the warehouse storage device and directly below the outlet. The core conveying device includes: a bottom truss, a rotating support assembly disposed on the bottom truss, a guide assembly, a traction assembly, and a hydraulic drive assembly. The bottom truss is located directly below the warehouse storage device. The rotating support assembly is disposed on the bottom truss and directly below the outlet. The traction assembly and the hydraulic drive assembly are respectively disposed at both ends of the bottom truss. A pressure sensor and a controller, wherein the pressure sensor is mounted on the rotary support assembly; The pressure sensor, the traction assembly, and the hydraulic drive assembly are all electrically connected to the controller. The discharge device includes a first motor, a coupling, and four rotating wheels. The output end of the first motor is connected to the four rotating wheels through the coupling. The four rotating wheels consist of a disc-shaped wheel body and several clamping parts arranged circumferentially around the wheel body. Each clamping part can clamp one heat exchange tube. Each clamping part is located at the outlet position as the wheel body rotates. The outlet includes a horizontal section and an inclined section. The horizontal section is used to place a single heat exchange tube. The rotation direction of the wheel body is from the horizontal section to the inclined section. The inclined section guides the direction of the outlet to the rotation support assembly. The traction assembly includes two pairs of drive rollers, which are positioned opposite each other and at a 60-degree angle to the horizontal. Each drive roller includes: Base; A servo motor is mounted on the base, and the output end of the servo motor is coaxially connected to a synchronous pulley. The output end of the synchronous pulley is coaxially connected to a non-shaped roller. A heat exchange tube can be accommodated between a pair of the irregularly shaped rollers; The irregular roller has a pair of protruding shaft ends at both ends, and each shaft end is provided with a movable slider, which can slide along the length direction of the shaft end.

2. The large heat exchanger tube core guide installation and transport mechanism according to claim 1, characterized in that, The rotational support assembly includes: Several sets of rollers are sequentially arranged on the bottom truss.

3. The large heat exchanger core guiding, installation and conveying mechanism according to claim 1, characterized in that, The hydraulic drive assembly includes a push hydraulic cylinder and a push head, the push head being disposed at the output end of the push hydraulic cylinder.

4. A large heat exchanger core guiding, installation, and conveying system, characterized in that: The system includes the large heat exchanger core guiding, installation and conveying mechanism as described in any one of claims 1-3.

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