A high pressure water descaling fluid control system

Abstract

The application discloses a high-pressure water descaling fluid control system, comprising a water tank, a filter, a three-plunger reciprocating pump, a circulating unloading valve, a high-pressure air compressor, an air-water accumulator, an accumulator pressure gauge, a minimum liquid level valve, a descaling injection valve, a nozzle manifold and a low-pressure air source. The application ensures stable medium pressure through the air-water accumulator, absorbs water hammer effect and reduces the flow requirement of the plunger pump. Meanwhile, the air control descaling injection valve is adopted to control the release of the medium in the accumulator, thereby improving the response speed during injection.

Description

Technical Field

[0001] This invention belongs to the field of automated forging technology, and in particular to a high-pressure water descaling fluid control system. Background Technology

[0002] Descaling of forgings is a crucial process in forging, beneficial to forging quality, die life, and production line energy consumption. Currently, most common descaling equipment uses low-pressure water, resulting in poor descaling efficiency and significant temperature drops, gradually failing to meet the demands of precision forging. To further improve oxide scale removal rates while saving energy, the requirements for the jet pressure of descaling machines are becoming increasingly stringent. The core of high-pressure water descaling technology lies in water pressurization jet technology, which, under safe conditions, pressurizes water to over 20 MPa, ensuring stable pressure and flow rate during intermittent operation to reduce water hammer effects. Currently, no existing technology solves these problems. Summary of the Invention

[0003] The purpose of this invention is to solve the problems of large fluctuations in medium pressure and flow rate and water hammer effect that can easily damage equipment during high-pressure water descaling. A high-pressure water descaling fluid control system is proposed, which uses a gas-water accumulator to ensure stable medium pressure, absorb the water hammer effect, and reduce the flow requirements of the plunger pump. At the same time, a pneumatically controlled descaling jet valve is used to control the release of medium in the accumulator, thereby improving the response speed during jetting.

[0004] The technical solution to achieve the purpose of this invention is as follows: On the one hand, a high-pressure water descaling fluid control system is provided, the system including a water tank, a filter, a three-plunger reciprocating pump, a circulating unloading valve, a high-pressure air compressor, a gas-water accumulator, an accumulator pressure gauge, a minimum liquid level valve, a descaling jet valve, a nozzle manifold and a low-pressure air source;

[0005] The filter inlet is connected to the water tank outlet via a pipeline. The inlet of the three-plunger reciprocating pump is connected to the filter outlet. The outlet of the three-plunger reciprocating pump is connected to the circulation unloading valve and the descaling jet valve, respectively. The circulation unloading valve is connected to a low-pressure air source, with one end connected to the outlet of the three-plunger reciprocating pump and the other end connected to the water tank return outlet. The high-pressure air compressor and the accumulator pressure gauge are connected to the air inlet of the gas-water accumulator. The gas-water accumulator inlet is connected to the inlet of the minimum liquid level valve. The outlet of the minimum liquid level valve is connected to the inlet of the descaling jet valve. The control end of the descaling jet valve is connected to the low-pressure air source, and the outlet end is connected to the nozzle manifold.

[0006] Furthermore, the filter is a backwash filter with a filtration accuracy of 0.1 mm.

[0007] Furthermore, the three-plunger reciprocating pump has a maximum output pressure of 25MPa and is equipped with an accumulator, a self-lubricating device, and an overflow valve.

[0008] Furthermore, the circulating unloading valve is a two-position two-way pneumatic control valve. Under load conditions, it is used to set the main pressure of the three-plunger reciprocating pump. Under unload conditions, the high-pressure water returns directly to the water tank, and the output pressure of the three-plunger reciprocating pump drops to near zero.

[0009] Furthermore, the output pressure of the high-pressure air compressor is matched with that of the three-plunger reciprocating pump, both being 25MPa, to achieve two-phase pressure balance within the gas-water accumulator.

[0010] Furthermore, the gas-water accumulator is equipped with an external liquid level gauge and is calibrated with four liquid level states: high-high liquid level A, normal high liquid level B, normal low liquid level C, and low-low liquid level D, wherein the volume between normal high liquid level B and normal low liquid level C is greater than the water consumption for a single descaling operation.

[0011] Furthermore, the closing pressure of the minimum liquid level valve is matched with the pressure of the gas-water accumulator at the low-low liquid level D state, both being 20MPa. When the pressure is higher than this, the valve core of the minimum liquid level valve opens, and when the pressure is lower than this, the valve core of the minimum liquid level valve closes.

[0012] Furthermore, the descaling injection valve is installed close to the nozzle manifold to reduce the injection response time.

[0013] Furthermore, the nozzle manifold is a closed loop, which can be square or round depending on the shape of the workpiece, and achieves full coverage of the workpiece surface by the high-pressure jet.

[0014] On the other hand, a high-pressure water descaling fluid control method is provided, the method comprising the following:

[0015] Energy storage stage of accumulator: When the liquid level in the gas-water accumulator is lower than the normal low liquid level C, the circulation unloading valve and the descaling jet valve are closed. The water in the tank is filtered by the filter and then pressurized to 25MPa by the three-plunger reciprocating pump. It is then connected to the minimum liquid level valve through pipeline ①. When the liquid pressure is greater than the closing pressure of the minimum liquid level valve (20MPa), the valve core of the minimum liquid level valve opens, and the gas-water accumulator begins to fill with liquid. When the normal high liquid level B is reached, the circulation unloading valve is opened, and the high-pressure water from the three-plunger reciprocating pump returns to the water tank through pipeline ②. The high-pressure air compressor works, and the gas in the gas-water accumulator is compressed to 25MPa, achieving gas-liquid balance.

[0016] Descaling stage: The descaling jet valve is opened, the circulation unloading valve is opened, and high-pressure water enters the pipeline ③ from the gas-water accumulator and is sprayed onto the workpiece surface through the nozzle manifold; as the high-pressure water jet is consumed, the liquid level in the gas-water accumulator gradually decreases, the gas volume increases, and the pressure decreases. After reaching the set value, the high-pressure air compressor works to compensate the gas pressure to 25MPa to ensure the stability of the descaling jet pressure.

[0017] Abnormal liquid level status: When the liquid level in the gas-water accumulator reaches the high-high level A, the system alarms and opens the circulation unloading valve and descaling injection valve until the liquid level drops to the normal high level B; when the liquid level in the gas-water accumulator reaches the low-low level D, the system alarms because the pressure inside the tank is released and falls below 20MPa, and the minimum liquid level valve closes to prevent compressed air from entering the liquid pipeline.

[0018] Compared with the prior art, the significant advantages of this invention are:

[0019] 1) Compared with the existing direct injection descaling system, the addition of an air-water accumulator in the descaling pipeline improves the pressure stability of high-pressure water, avoids water hammer effect damage to pipelines and nozzles, and also reduces the flow requirements of the three-plunger reciprocating pump.

[0020] 2) Combining the intermittent spray characteristics of the descaling system, the load of the three-plunger reciprocating pump is changed by using a circulating unloading valve, thus achieving the energy-saving requirement of the three-plunger reciprocating pump without repeated start-stop.

[0021] The present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a high-pressure water descaling fluid control system according to one embodiment of the present invention.

[0023] The attached diagram lists the components represented by each number as follows:

[0024] 1-Water tank, 2-Filter, 3-Three-plunger reciprocating pump, 4-Circulation unloading valve, 5-High-pressure air compressor, 6-Air-water accumulator, 7-Accumulator pressure gauge, 8-Minimum level valve, 9-Descaling injection valve, 10-Nozzle manifold, 11-Low-pressure air source Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0026] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0027] In one embodiment, combined Figure 1A high-pressure water descaling fluid control system is provided, including a water tank 1, a filter 2, a three-plunger reciprocating pump 3, a circulating unloading valve 4, a high-pressure air compressor 5, a gas-water accumulator 6, an accumulator pressure gauge 7, a minimum liquid level valve 8, a descaling jet valve 9, a nozzle manifold 10, and a low-pressure air source 11.

[0028] The inlet of the filter 2 is connected to the outlet of the water tank 1 via a pipeline. The inlet of the three-plunger reciprocating pump 3 is connected to the outlet of the filter 2. The outlet of the three-plunger reciprocating pump 3 is connected to the circulation unloading valve 4 and the descaling jet valve 9 respectively. The circulation unloading valve 4 is connected to the low-pressure air source 11, with one end connected to the outlet of the three-plunger reciprocating pump 3 and the other end connected to the return water outlet of the water tank 1. The high-pressure air compressor 5 and the accumulator pressure gauge 7 are connected to the air inlet of the gas-water accumulator 6. The inlet of the gas-water accumulator 6 is connected to the inlet of the minimum liquid level valve 8. The outlet of the minimum liquid level valve 8 is connected to the inlet of the descaling jet valve 9. The control end of the descaling jet valve 9 is connected to the low-pressure air source 11, and the outlet end is connected to the nozzle manifold 10.

[0029] More preferably, in one embodiment, the filter 2 is a backwash filter with a filtration accuracy of 0.1 mm, which can reduce the risk of system clogging.

[0030] More preferably, in one embodiment, the three-plunger reciprocating pump 3 has a maximum output pressure of 25 MPa and is equipped with an accumulator, a self-lubricating device, and an overflow valve to improve its service life.

[0031] More preferably, in one embodiment, the circulating unloading valve 4 is a two-position two-way pneumatic control valve. In the load state, it is used to set the main pressure of the three-plunger reciprocating pump 3. In the unload state, the high-pressure water returns directly to the water tank 1, and the output pressure of the three-plunger reciprocating pump 3 drops to approximately zero, so as to realize some loop control and improve the life of the oil pump and reduce power consumption.

[0032] More preferably, in one embodiment, the output pressure of the high-pressure air compressor 5 is matched with that of the three-plunger reciprocating pump 3, both being 25 MPa, to achieve two-phase pressure balance within the gas-water accumulator 6.

[0033] More preferably, in one embodiment, the gas-water accumulator 6 is equipped with an external level gauge and calibrated with four level states: high-high level A, normal high level B, normal low level C, and low-low level D. The volume between normal high level B and normal low level C is greater than the water consumption for a single descaling operation.

[0034] More preferably, in one embodiment, the closing pressure of the minimum liquid level valve 8 is matched with the pressure of the gas-water accumulator 6 at the low liquid level D state, both being 20 MPa. When the pressure is higher than this, the valve core opens; when the pressure is lower than this, the valve core closes.

[0035] More preferably, in one embodiment, the descaling spray valve 9 is installed close to the nozzle manifold 10, which can reduce the spray response time.

[0036] More preferably, in one embodiment, the nozzle manifold 10 is a closed ring, which can be square or round depending on the shape of the workpiece, to ensure that the high-pressure jet fully covers the surface of the workpiece.

[0037] In one embodiment, a control method for a high-pressure water descaling fluid control system is provided, as follows:

[0038] Energy storage stage of accumulator: When the liquid level in the gas-water accumulator 6 is lower than the normal low liquid level C, the circulation unloading valve 4 and the descaling jet valve 9 are closed. The water in the water tank 1 is filtered by the filter 2 and then pressurized to 25MPa by the three-plunger reciprocating pump 3. It is then connected to the minimum liquid level valve 8 through pipeline ①. When the liquid pressure is greater than the closing pressure of the minimum liquid level valve 8 by 20MPa, the valve core opens and the gas-water accumulator 6 begins to fill with liquid. When the normal high liquid level B is reached, the circulation unloading valve 4 is opened, and the high-pressure water from the three-plunger reciprocating pump 3 returns to the water tank through pipeline ②. The high-pressure air compressor 5 works, and the gas in the gas-water accumulator 6 is compressed to 25MPa, achieving gas-liquid balance.

[0039] Descaling stage: Descaling jet valve 9 opens, circulation unloading valve 4 opens, high-pressure water enters pipeline ③ from gas-water accumulator 6, and is sprayed onto the workpiece surface through nozzle manifold 10; as the high-pressure water jet is consumed, the liquid level in gas-water accumulator 6 gradually decreases, the gas volume increases, and the pressure decreases. After reaching the set value, high-pressure air compressor 5 works to compensate the gas pressure to 25MPa, ensuring the stability of descaling jet pressure;

[0040] Abnormal liquid level status: When the liquid level in the gas-water accumulator 6 reaches the high-high liquid level A, the system alarms and opens the circulation unloading valve 4 and the descaling jet valve 9 until the liquid level drops to the normal high liquid level B; when the liquid level in the gas-water accumulator 6 reaches the low-low liquid level D, the system alarms. Due to the release of pressure inside the tank, which is below 20MPa, the minimum liquid level valve 8 closes to prevent compressed air from entering the liquid pipeline.

[0041] The high-pressure descaling fluid control system proposed in this invention, compared with the existing direct injection descaling system, improves the pressure stability of high-pressure water by adding a gas-water accumulator in the descaling pipeline, avoids water hammer effect damage to pipelines and nozzles, and also reduces the flow requirements of the three-plunger reciprocating pump. Combining the intermittent injection characteristics of the descaling system, the load of the three-plunger reciprocating pump is changed by using a circulating unloading valve, thereby achieving energy-saving requirements without the need for repeated start-stop of the three-plunger reciprocating pump.

[0042] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A high-pressure water descaling fluid control system, characterized in that, The system includes a water tank (1), a filter (2), a three-plunger reciprocating pump (3), a circulating unloading valve (4), a high-pressure air compressor (5), a gas-water accumulator (6), an accumulator pressure gauge (7), a minimum liquid level valve (8), a descaling jet valve (9), a nozzle manifold (10), and a low-pressure air source (11). The inlet of the filter (2) is connected to the outlet of the water tank (1) through a pipeline. The inlet of the three-plunger reciprocating pump (3) is connected to the outlet of the filter (2). The outlet of the three-plunger reciprocating pump (3) is connected to the circulation unloading valve (4) and the descaling jet valve (9) respectively. The circulation unloading valve (4) is connected to the low-pressure air source (11). One end of the circulation unloading valve (4) is connected to the outlet of the three-plunger reciprocating pump (3), and the other end is connected to the return water port of the water tank (1). The high-pressure air compressor (5) and the accumulator pressure gauge (7) are connected to the air inlet of the gas-water accumulator (6). The inlet of the gas-water accumulator (6) is connected to the inlet of the minimum liquid level valve (8). The outlet of the minimum liquid level valve (8) is connected to the inlet of the descaling jet valve (9). The control end of the descaling jet valve (9) is connected to the low-pressure air source (11), and the outlet end is connected to the nozzle manifold (10). A high-pressure water descaling fluid control method based on the aforementioned system, the method comprising the following: Energy storage stage of accumulator: When the liquid level in the gas-water accumulator (6) is lower than the normal low liquid level C, the circulation unloading valve (4) and the descaling jet valve (9) are closed. The water in the water tank (1) is filtered by the filter (2) and then pressurized to 25MPa by the three-plunger reciprocating pump (3). It is connected to the minimum liquid level valve (8) through pipeline ①. When the liquid pressure is greater than the closing pressure of the minimum liquid level valve (8) by 20MPa, the valve core of the minimum liquid level valve (8) is opened, and the gas-water accumulator (6) begins to fill with liquid. When the normal high liquid level B is reached, the circulation unloading valve (4) is opened. The high pressure water of the three-plunger reciprocating pump (3) returns to the water tank (1) through pipeline ②. The high pressure air compressor (5) works, and the gas in the gas-water accumulator (6) is compressed to 25MPa to achieve gas-liquid balance. Descaling stage: The descaling jet valve (9) is opened, the circulation unloading valve (4) is opened, and high-pressure water enters the pipeline ③ from the gas-water accumulator (6) and is sprayed onto the workpiece surface through the nozzle manifold (10). As the high-pressure water jet is consumed, the liquid level in the gas-water accumulator (6) gradually decreases, the gas volume increases, and the pressure decreases. After reaching the set value, the high-pressure air compressor (5) works to compensate the gas pressure to 25MPa to ensure the stability of the descaling jet pressure. Abnormal liquid level status: When the liquid level in the gas-water accumulator (6) reaches the high-high liquid level A, the system alarms and opens the circulation unloading valve (4) and the descaling jet valve (9) until the liquid level drops to the normal high liquid level B; when the liquid level in the gas-water accumulator (6) reaches the low-low liquid level D, the system alarms. Due to the release of pressure in the tank, it is lower than 20MPa, and the minimum liquid level valve (8) is closed to prevent compressed air from entering the liquid pipeline.

2. The high-pressure water descaling fluid control system according to claim 1, characterized in that, The filter (2) is a backwash filter with a filtration accuracy of 0.1 mm.

3. The high-pressure water descaling fluid control system according to claim 1, characterized in that, The three-plunger reciprocating pump (3) has a maximum output pressure of 25MPa and is equipped with an accumulator, a self-lubricating device and an overflow valve.

4. The high-pressure water descaling fluid control system according to claim 1, characterized in that, The circulating unloading valve (4) is a two-position two-way air control valve. In the load state, it is used to set the main pressure of the three-plunger reciprocating pump (3). In the unloading state, the high-pressure water returns directly to the water tank (1), and the output pressure of the three-plunger reciprocating pump (3) drops to close to zero.

5. The high-pressure water descaling fluid control system according to claim 1, characterized in that, The output pressure of the high-pressure air compressor (5) is matched with that of the three-plunger reciprocating pump (3), both being 25MPa, in order to achieve two-phase pressure balance in the gas-water accumulator (6).

6. The high-pressure water descaling fluid control system according to claim 1, characterized in that, The gas-water accumulator (6) is equipped with an external liquid level gauge and is calibrated with four liquid level states: high-high liquid level A, normal high liquid level B, normal low liquid level C, and low-low liquid level D. The volume between normal high liquid level B and normal low liquid level C is greater than the water consumption for a single descaling operation.

7. The high-pressure water descaling fluid control system according to claim 6, characterized in that, The closing pressure of the minimum liquid level valve (8) is matched with the pressure of the gas-water accumulator (6) in the low-low liquid level D state, both being 20MPa. When the pressure is higher than this, the valve core of the minimum liquid level valve (8) opens, and when the pressure is lower than this, the valve core of the minimum liquid level valve (8) closes.

8. The high-pressure water descaling fluid control system according to claim 1, characterized in that, The descaling injection valve (9) is installed close to the nozzle manifold (10) to reduce the injection response time.

9. The high-pressure water descaling fluid control system according to claim 8, characterized in that, The nozzle manifold (10) is a closed ring, which can be square or round depending on the shape of the workpiece, and can achieve full coverage of the workpiece surface by the high-pressure jet.

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