Energy-saving titanium alloy heat exchanger and installation method thereof

Abstract

The present invention relates to the technical field of heat exchangers, and discloses an energy-saving titanium alloy heat exchanger and an installation method thereof, comprising: a shell; an upper tube plate, located on the left side of the shell; a lower tube plate, located on the right side of the shell; a slip-on flange, fixed to the shell and detachable from the upper plate tube; an installation mechanism, located below the shell; a pull rod is fixedly connected to the side of the upper tube plate close to the shell, and multiple groups of baffles are sequentially installed on the outer side wall of the pull rod; by first installing one side of the tube plate and then using a guide head to penetrate the other side of the tube plate during the installation process, the guide head installs the titanium heat exchange tube, thereby reducing the installation difficulty, and ensuring a stable connection between the tube plate and the shell through the installation mechanism, thereby improving the convenience of weld detection, ensuring a reliable connection between the tube plate and the shell, and meeting the AD2000 requirements for radiographic detection, ensuring the reliability of the shell weld, and not needing to lengthen the heat exchange tube during the installation process, thereby avoiding waste and reducing manufacturing costs.

Description

Technical Field

[0001] The present invention relates to the technical field of heat exchangers, in particular to an energy-saving titanium alloy heat exchanger and an installation method thereof. Background Art

[0002] In heat exchanger manufacturing, the AD2000 design specification requires strict radiographic testing of shell butt joints to ensure weld quality. Titanium heat exchangers have higher requirements for welding quality due to the material's characteristics and the high-temperature, high-pressure operating environment. In a fixed-tube-sheet heat exchanger structure where the heat exchange tubes and tube sheets are deep-hole welded on one end and fillet welded on the other, the shell is stuck between the two tube sheets. One section of the cylinder needs to be left unwelded to make room for deep-hole welding of the heat exchange tubes. The last section of the cylinder needs to be split into two halves and then welded and installed. After the shell is welded, it is impossible to enter the interior, making it difficult to conduct comprehensive radiographic testing of the shell. According to GB150 and ASME specifications, ultrasonic testing can be used instead of radiographic testing to solve flaw detection problems, but the AD2000 specification does not allow ultrasonic testing of titanium.

[0003] In view of the above problems, an energy-saving titanium alloy heat exchanger and an installation method thereof are proposed. Summary of the Invention

[0004] The purpose of the present invention is to provide an energy-saving titanium alloy heat exchanger and an installation method thereof, which solves the problems in the background art of ensuring convenient detection and stable installation of titanium heat exchange tubes and tube sheets.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: an energy-saving titanium alloy heat exchanger, comprising: a shell; an upper tube plate, located on the left side of the shell; a lower tube plate, located on the right side of the shell; a slip-on flange, fixed to the shell and removable from the upper plate tube; a mounting mechanism, located below the shell; the upper tube plate is fixedly connected to a pull rod on one side close to the shell, and multiple groups of baffles are sequentially installed on the outer wall of the pull rod, and a heat exchange tube is welded to a heat exchange tube through a boss on the side of the upper tube plate close to the shell, and the heat exchange tube passes through the baffle, and a lower tube hole is opened on the side of the lower tube plate close to the shell, and a guide head is installed inside the lower tube hole, and the guide head is detachably connected to the heat exchange tube; the mounting mechanism includes a mounting base, a bracket, a positioning sleeve, a front support plate and a rear support plate, and a mounting base is provided below the shell, and two groups of brackets are fixedly connected to the upper surface of the mounting base, and the bracket is connected to the positioning sleeve by a first motor rotation, and the positioning sleeve contacts the shell, and the mounting base is slidably connected to the front support plate and the rear support plate through two groups of adjustment mechanisms.

[0006] As a further description of the above technical solution: the adjusting mechanism includes a second motor, a screw, a screw block and an adjusting plate, the upper surface of the mounting base is rotatably connected to the screw through the second motor, the outer wall of the screw is threadedly connected to the screw block, the top of the screw block located on one side of the upper tube plate is fixedly connected to the front support plate, the screw block located on one side of the lower tube plate is rotatably connected to the rear support plate through an auxiliary mechanism, the opposite sides of the front support plate and the rear support plate are fixedly connected to the adjusting plates, an extrusion mechanism is provided above the adjusting plate, the length of the screw in the adjusting mechanism is adapted to the distance between the upper tube plate and the shell, the upper surface of the mounting base is fixedly connected to the limiting plate, the limiting plate is rotatably connected to the screw, and the opposite sides of the front support plate and the rear support plate are fixedly connected to the friction pad.

[0007] As a further description of the above technical solution: the extrusion mechanism includes a bidirectional telescopic rod, a lifting block, an extrusion block and a first matching part. The top of the screw block is slidably connected to the bidirectional telescopic rod through a slider, both ends of the bidirectional telescopic rod are fixedly connected to the lifting block, the top of the bidirectional telescopic rod is fixedly connected to the extrusion block through an extension mechanism, the first matching part is rotatably connected between the extrusion block and the lifting block, the upper surface of the screw block is fixedly connected to a rotating shaft, and the second matching part is rotatably connected between the lifting block and the rotating shaft.

[0008] As a further description of the above technical solution: the extension mechanism includes an extension tube and an extension rod, the outer side wall of the two-way telescopic rod is fixedly connected to the extension tube, the interior of the extension tube is slidably connected to the extension rod, and the extension rod is fixedly connected to the extrusion block.

[0009] As a further description of the above technical solution: the auxiliary mechanism includes an extension block and an extension motor, the front end and the rear end of the screw block located on one side of the lower tube plate are fixedly connected to the extension block, the extension motor is embedded in the extension block, the output shaft of the extension motor is fixedly connected to the rear support plate, the side of the rear support plate close to the shell is fixedly connected to an electromagnetic ring, and the electromagnetic ring is electromagnetically adsorbed to the guide head.

[0010] A method for installing an energy-saving titanium alloy heat exchanger comprises the following steps:

[0011] S1. Perform radiographic inspection on the weld seams of the shell according to the AD2000 design specification to ensure that the quality of the weld seams meets the standard requirements and place it between the two positioning sleeves;

[0012] S2, by synchronously starting the two sets of second motors, the front support plate and the rear support plate are driven to move relative to each other, the position of the shell is corrected to make it the center point, and then the front support plate and the rear support plate are reset;

[0013] S3. Weld one side of the upper tube plate to the tie rod, install the baffles in sequence, and then install a small number of heat exchange tubes through the bosses for positioning;

[0014] S4. Place the upper tube sheet above the adjustment plate, contact one side with the front support plate, and then retract the bidirectional telescopic rod to drive the slider to move toward the upper tube sheet. The first actuator drives the extrusion block to rise and contact and squeeze the upper tube sheet. Insert the remaining heat exchange tubes into the bosses for welding. Then, the second motor pushes the upper tube sheet into the shell.

[0015] S5. The rear support plate is rotated by the extension motor, and the guide head is installed and magnetically attracted in the electromagnetic ring. After the lower tube plate and the guide head are aligned and installed, the rear support plate is reset. The extrusion mechanism is repeated, and the lower tube plate is pushed into the shell through the adjustment mechanism. The guide head is engaged with the heat exchange tube and then guided into the lower tube plate.

[0016] S6. Weld the upper tube sheet and the lower tube sheet to the shell, and perform fillet welds on the heat exchange tubes and the lower tube sheet.

[0017] As a further description of the above technical solution: the step of performing radiographic inspection on the weld of the shell according to the AD2000 design specification in step S1 includes:

[0018] S11. Clean the weld surface, place the X-ray source on one side of the weld, and the digital detector on the opposite side;

[0019] S12, selecting a suitable radiation transmission time according to the thickness and shape of the weld, and starting exposure according to the radiation transmission time to obtain a digital image of the weld;

[0020] S13, performing noise removal, contrast enhancement, and brightness adjustment on the digital image of the weld in sequence to obtain a preprocessed weld image;

[0021] S14, using edge detection technology to analyze and identify the pre-processed weld image to obtain all defect types;

[0022] S15. Obtain corresponding defect features according to each defect type, and obtain weld quality according to the plurality of defect features;

[0023] S16, determining whether the weld quality is less than a preset quality;

[0024] If the weld quality is less than the preset quality, it is determined that the weld quality does not meet the standard specification requirements;

[0025] If the weld quality is not less than the preset quality, the weld quality is judged to meet the standard specification requirements.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] The present invention provides an energy-saving titanium alloy heat exchanger and an installation method thereof. During the installation process, the tube sheet on one side is first installed and then a guide head is used to penetrate the tube sheet on the other side. The guide head installs the titanium heat exchange tube, thereby reducing the difficulty of installation. The installation mechanism ensures a stable connection between the tube sheet and the shell, improves the convenience of weld detection, and ensures a reliable connection between the tube sheet and the shell. It also meets the AD2000 requirements for radiographic detection, ensures the reliability of the shell weld, and does not require lengthening the heat exchange tube during installation, thereby avoiding waste and reducing manufacturing costs.

[0028] The present invention provides an energy-saving titanium alloy heat exchanger and an installation method thereof. The installation mechanism avoids the traditional manual pushing and installation of the upper tube plate and the lower tube plate, thereby increasing the convenience and efficiency of the work. The shell is located at the center through the adjustment mechanism and the limit plate, and the positions of the upper tube plate and the lower tube plate are fixed and limited during installation, thereby ensuring the convenience of subsequent welding.

[0029] The present invention provides an energy-saving titanium alloy heat exchanger and an installation method thereof. By calculating the appropriate exposure amount and transmission time, the quality of the weld image can be ensured, inappropriate exposure conditions can be avoided, and appropriate image brightness and contrast can be obtained. While ensuring image quality, the recognition of defects can be improved. By controlling the radiation transmission time, image blurring or distortion can be avoided, thereby enhancing the accuracy of defect detection.

[0030] The present invention provides an energy-saving titanium alloy heat exchanger and an installation method thereof. Through multi-dimensional feature analysis of defect area, defect aspect ratio, defect roundness, defect edge roughness and defect depth, defects in the weld can be evaluated more comprehensively and accurately, thereby avoiding the error or one-sidedness caused by a single indicator. By assigning a weight value to each defect, the severity of various defects in the weld can be quantified more accurately, helping to automatically determine whether the weld meets the quality standards, reducing human errors, and improving consistency and standardization. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0032] Figure 2 Schematic diagram of the internal structure of the present invention;

[0033] Figure 3 Schematic diagram of the structure of the adjustment mechanism of the present invention;

[0034] Figure 4 For the present invention Figure 3 Schematic diagram of the structure at A;

[0035] Figure 5 Schematic diagram of the structure of the auxiliary mechanism in the present invention;

[0036] Figure 6 This is an installation flow chart of the present invention;

[0037] Figure 7 This is a flow chart of weld detection in the present invention.

[0038] Figure: 1, shell; 2, upper tube plate; 3, lower tube plate; 4, slip-on flange; 5, mounting mechanism; 501, mounting base; 502, bracket; 503, positioning sleeve; 504, front support plate; 505, rear support plate; 506, first motor; 6, pull rod; 7, baffle; 8, boss; 9, heat exchange tube; 10, lower tube hole; 11, guide head; 12, adjustment mechanism; 1201, second motor; 1202, screw; 1203, screw block; 120 4. Adjustment plate; 13. Extrusion mechanism; 1301. Bidirectional telescopic rod; 1302. Lifting block; 1303. Extrusion block; 1304. First movable member; 1305. Slider; 1306. Rotating shaft; 1307. Second movable member; 14. Extension mechanism; 1401. Extension cylinder; 1402. Extension rod; 15. Auxiliary mechanism; 1501. Extension block; 1502. Extension motor; 1503. Electromagnetic ring; 16. Limit plate; 17. Friction pad. DETAILED DESCRIPTION

[0039] The following will provide a clear and complete description of the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0040] In order to further understand the content of the present invention, the present invention is described in detail with reference to the accompanying drawings.

[0041] Combine Figure 1 、 Figure 2 、 Figure 3 and Figure 4 An energy-saving titanium alloy heat exchanger includes: a shell 1; an upper tube sheet 2, located on the left side of the shell 1; a lower tube sheet 3, located on the right side of the shell 1; a slip-on flange 4, fixed to the shell 1 and detachable from the upper tube sheet 2; a mounting mechanism 5, located below the shell 1; a pull rod 6 is fixedly connected to the side of the upper tube sheet 2 close to the shell 1, and multiple groups of baffles 7 are sequentially installed on the outer wall of the pull rod 6; a heat exchange tube 9 is welded to the side of the upper tube sheet 2 close to the shell 1 through a boss 8, and the heat exchange tube 9 passes through the baffle 7; a lower tube hole 10 is opened on the side of the lower tube sheet 3 close to the shell 1, and a guide head 11 is installed inside the lower tube hole 10, and the guide head 11 is detachably connected to the heat exchange tube 9,

[0042] The shell 1 is subjected to radiographic inspection of the welds according to the AD2000 design specification to ensure that the quality of the welds meets the standard specification requirements; one side of the upper tube plate 2 is welded to the tie rod 6, the baffles 7 are installed in sequence, and then a small amount of heat exchange tubes 9 are installed through the bosses 8 for positioning, the lower tube plate 3 is inserted into the guide head 11, and then the heat exchange tubes 9 are guided into the lower tube plate 3 through the guide head 11 and the heat exchange tubes 9 corresponding to the heat exchange tubes 9 on one side of the upper tube plate 2, and the upper tube plate 2 and the lower tube plate 3 are welded to the shell 1, and the heat exchange tubes 9 are welded to the lower tube plate 3 with fillet welds.

[0043] Combine Figure 3 and Figure 4 The mounting mechanism 5 includes a mounting base 501, a bracket 502, a positioning sleeve 503, a front support plate 504 and a rear support plate 505. The mounting base 501 is provided below the shell 1. The upper surface of the mounting base 501 is fixedly connected with two sets of brackets 502. The bracket 502 is rotated by the first motor 506 and connected with the positioning sleeve 503. The positioning sleeve 503 is in contact with the shell 1. The mounting base 501 is slidably connected with the front support plate 504 and the rear support plate 505 through two sets of adjustment mechanisms 12. The adjustment mechanism 12 includes a second motor 1201, a screw 1202, a screw block 1 203 and the adjustment plate 1204, the upper surface of the mounting base 501 is connected to the screw rod 1202 by the second motor 1201, the outer wall of the screw rod 1202 is threadedly connected to the screw block 1203, the top of the screw block 1203 on the side of the upper tube plate 2 is fixedly connected to the front support plate 504, and the screw block 1203 on the side of the lower tube plate 3 is rotatably connected to the rear support plate 505 through the auxiliary mechanism 15, the opposite sides of the front support plate 504 and the rear support plate 505 are fixedly connected to the adjustment plate 1204, and the upper side of the adjustment plate 1204 is provided with an extrusion mechanism 13, the extrusion mechanism 13 The invention comprises a bidirectional telescopic rod 1301, a lifting block 1302, an extrusion block 1303 and a first matching member 1304. The upper surface of the screw block 1203 is slidably connected to the bidirectional telescopic rod 1301 through a slider 1305. Both ends of the bidirectional telescopic rod 1301 are fixedly connected to the lifting block 1302. The top of the bidirectional telescopic rod 1301 is fixedly connected to the extrusion block 1303 through an extension mechanism 14. The first matching member 1304 is rotatably connected between the extrusion block 1303 and the lifting block 1302. The upper surface of the screw block 1203 is fixedly connected to the rotating shaft 1306. The lifting block 1 A second displacing member 1307 is rotatably connected between 302 and the rotating shaft 1306. The extension mechanism 14 includes an extension tube 1401 and an extension rod 1402. The outer wall of the bidirectional telescopic rod 1301 is fixedly connected to the extension tube 1401. The extension rod 1402 is slidably connected to the interior of the extension tube 1401. The extension rod 1402 is fixedly connected to the extrusion block 1303. The upper surface of the mounting base 501 is fixedly connected to a limit plate 16, which is rotatably connected to the screw 1202. Friction pads 17 are fixedly connected to the opposite sides of the front support plate 504 and the rear support plate 505.

[0044] The two sets of second motors 1201 are started synchronously to drive the front support plate 504 and the rear support plate 505 to move relative to each other, and the position of the shell 1 is corrected to make it the center point. Then the front support plate 504 and the rear support plate 505 are reset, and the upper tube plate 2 is placed above the adjustment plate 1204. The front support plate 504 contacts one side, and then the two-way telescopic rod 1301 is contracted to drive the slider 1305 to move toward the upper tube plate 2, and the first movable member 1304 drives the extrusion block 1303 to rise and contact and extrude the upper tube plate 2, and the remaining heat exchange tubes 9 are inserted into the boss 8 for welding, and then the upper tube plate 2 is pushed to the end of the shell 1 by the second motor 1201.

[0045] Combine Figure 1 and Figure 5 The auxiliary mechanism 15 includes an extension block 1501 and an extension motor 1502. The front and rear ends of the screw block 1203 on one side of the lower tube plate 3 are fixedly connected with the extension block 1501. The extension motor 1502 is embedded in the extension block 1501. The output shaft of the extension motor 1502 is fixedly connected with the rear support plate 505. The side of the rear support plate 505 close to the shell 1 is fixedly connected with an electromagnetic ring 1503. The electromagnetic ring 1503 is electromagnetically adsorbed with the guide head 11. The rear support plate 505 is driven by the extension motor 1502 to rotate to a suitable installation position of the guide head 11 to facilitate the installation of the guide head 11 and the subsequent separation from the heat exchange tube 9.

[0046] A method for installing an energy-saving titanium alloy heat exchanger comprises the following steps:

[0047] S1. Perform radiographic inspection on the weld seam of the shell 1 according to the AD2000 design specification to ensure that the quality of the weld seam meets the standard specification requirements and place it between the two positioning sleeves 503;

[0048] S2. The two second motors 1201 are started synchronously to drive the front support plate 504 and the rear support plate 505 to move relative to each other, and the position of the housing 1 is corrected to make it the center point, and then the front support plate 504 and the rear support plate 505 are reset;

[0049] S3. Weld one side of the upper tube plate 2 to the tie rod 6, install the baffles 7 in sequence, and then install the heat exchange tubes 9 through the bosses 8 in small quantities for positioning;

[0050] S4. Place the upper tube sheet 2 above the adjustment plate 1204, contacting one side with the front support plate 504. Then, the bidirectional telescopic rod 1301 contracts, driving the slider 1305 to move toward the upper tube sheet 2. The first movable member 1304 drives the extrusion block 1303 to rise and contact and extrude the upper tube sheet 2. Insert the remaining heat exchange tubes 9 into the boss 8 for welding. Then, the second motor 1201 pushes the upper tube sheet 2 to the end of the shell 1.

[0051] S5. The rear support plate 505 is rotated by extending the motor 1502, and the guide head 11 is installed and magnetically attracted to the electromagnetic ring 1503. The lower tube plate 3 and the guide head 11 are then aligned and installed, and the rear support plate 505 is reset. The squeezing mechanism 13 is repeated, and the lower tube plate 3 is pushed into the shell 1 by the adjustment mechanism 12. The guide head 11 engages with the heat exchange tube 9 and is then guided into the lower tube plate 3.

[0052] S6. Weld the upper tube sheet 2 and the lower tube sheet 3 to the shell 1, and perform fillet welding on the heat exchange tube 9 and the lower tube sheet 3.

[0053] Furthermore, the step of performing radiographic inspection on the weld of the shell 1 according to the AD2000 design specification in step S1 includes:

[0054] S11. Clean the weld surface, place the X-ray source on one side of the weld, and the digital detector on the opposite side;

[0055] S12, selecting a suitable radiation transmission time according to the thickness and shape of the weld, and starting exposure according to the radiation transmission time to obtain a digital image of the weld;

[0056] S13, performing noise removal, contrast enhancement, and brightness adjustment on the digital image of the weld in sequence to obtain a preprocessed weld image;

[0057] S14, using edge detection technology to analyze and identify the pre-processed weld image to obtain all defect types;

[0058] S15. Obtain corresponding defect features according to each defect type, and obtain weld quality according to the plurality of defect features;

[0059] S16, determining whether the weld quality is less than a preset quality;

[0060] If the weld quality is less than the preset quality, it is determined that the weld quality does not meet the standard specification requirements;

[0061] If the weld quality is not less than the preset quality, the weld quality is judged to meet the standard specification requirements.

[0062] As described in the above steps S11-S16, in the present invention, the weld surface is cleaned, a suitable radiation transmission time is selected according to the thickness and shape of the weld, and exposure is started according to the radiation transmission time to obtain a weld digital image, and the weld digital image is subjected to denoising, contrast enhancement and brightness adjustment in sequence to obtain a pre-processed weld image. The radiation transmission imaging of the weld may be interfered with by various noises (such as electronic noise, scattering, etc.), which may cause the image quality to deteriorate and affect the identification of defects. By denoising, these interferences can be reduced or eliminated, thereby obtaining a clearer and more realistic weld image, which helps to improve the recognizability of weld defects. Defects in the weld are usually less different from the density or thickness of the surrounding metal, but may There are still certain differences. By enhancing the contrast of the image, these subtle differences can be made more obvious, thereby distinguishing the defective area from the rest of the weld. The brightness of the weld image may be affected by many factors (such as exposure time, material type, radiation intensity, etc.). By adjusting the brightness processing, the visibility of the image can be improved to ensure that the details of the weld are not unrecognizable due to being too dark or too bright. Welds of different thicknesses and shapes may require different radiation transmission times to obtain the best imaging effect. If the radiation transmission time is too short or too long, the image may be too blurred or insufficient to penetrate the weld, affecting the display of defects. By reasonably selecting the radiation transmission time, it can be ensured that the digital image of the weld is exposed under optimal conditions to avoid overexposure. Or underexposure, ensure the high quality of the weld image, thereby improving the accuracy of defect detection. Through the automated image preprocessing process, the influence of human factors can be effectively reduced, the automation level of the detection system can be improved, and the accuracy and consistency of the detection can be improved, making the detection process more efficient, reducing errors, and ensuring that the weld quality meets the standard requirements. In the present invention, the preprocessed weld image is analyzed and identified by using edge detection technology to obtain all defect types, and the corresponding defect features are obtained according to each defect type. The weld quality is obtained according to multiple defect features, and it is judged whether the weld quality is less than the preset quality. If the weld quality is less than the preset quality, it is determined that the weld quality does not meet the standard specification requirements. If the weld quality is not less than the preset quality, it is determined that the weld quality does not meet the standard specification requirements. , it is determined that the weld quality meets the standard specification requirements. The edge detection technology is used to analyze the weld image, which can automatically identify the weld defects in the image, avoiding the subjectivity and efficiency problems of manual inspection. The edge detection technology can extract the key features in the weld image and identify different types of defects (such as cracks, pores, slag inclusions, etc.) through image analysis. By extracting the characteristics of each defect and combining the comprehensive analysis of multiple defect characteristics, the overall quality of the weld can be quantified. By setting a standard quality value and automatically judging whether the weld meets this standard, the misjudgment or missed judgment that may occur in manual inspection is avoided. For some small or hidden defects that are difficult to detect with traditional manual methods, edge detection technology and image processing technology can accurately identify them.Especially in complex areas such as the inside of welds or corners, computer vision can detect subtle defects that are difficult to detect with traditional methods through high-precision image recognition.

[0063] Furthermore, the step of selecting a suitable radiation transmission time according to the thickness and shape of the weld in step S12 includes:

[0064] S121. Obtaining the required exposure and characteristic parameters of the weld, wherein the characteristic parameters include the weld radiation absorption coefficient and the weld thickness;

[0065] S122. Obtain the initial intensity of the radiation source, and calculate the radiation transmission time according to the required exposure, the initial intensity of the radiation source, the weld radiation absorption coefficient, and the weld thickness, wherein the calculation formula is:

[0066] ;

[0067] in, represents the radiation transmission time, Indicates the required exposure, represents the initial intensity of the ray source, represents the weld ray absorption coefficient, Indicates the weld thickness.

[0068] As described in the above steps S11-S16, in the present invention, by obtaining the required exposure of the weld and the weld radiation absorption coefficient and weld thickness of the characteristic parameters, by obtaining the initial intensity of the radiation source, and calculating the radiation transmission time according to the required exposure, the initial intensity of the radiation source, the weld radiation absorption coefficient and the weld thickness, the radiation detection of the weld requires an appropriate exposure to obtain a clear image. If the exposure is insufficient, the image may be too dark and the defects cannot be fully displayed; if the exposure is too high, the image may be overexposed, affecting the recognition of details. By calculating the appropriate exposure and transmission time, the quality of the weld image can be ensured, inappropriate exposure conditions can be avoided, and appropriate image brightness and contrast can be obtained. While ensuring the image quality, the recognition of defects can be improved, and image quality problems caused by insufficient or excessive exposure can be avoided, thereby improving the quality of the weld image. The accuracy of detection can be improved by considering the radiation absorption coefficient, thickness and initial intensity of the radiation source of the weld to accurately calculate the required radiation transmission time. By controlling the radiation transmission time, image blur or distortion can be avoided, thereby enhancing the accuracy of defect detection, especially for the detection of more complex weld structures and small-sized defects. In traditional radiographic detection, the exposure time often depends on manual settings and may be affected by factors such as the environment and operator experience. By relying on accurate mathematical calculations to determine the exposure amount and transmission time, the deviation of human operation is reduced, the accuracy and consistency of detection are improved, and the inconsistent exposure settings caused by different operator experience or environmental factors are avoided, thereby ensuring the objectivity and reliability of weld quality judgment. The material, thickness and radiation absorption coefficient of the weld are important factors affecting the radiation transmission time. By obtaining these parameters, the exposure and transmission time can be automatically adjusted according to the specific characteristics of the weld, ensuring the best imaging effect in various materials and thicknesses, adapting to the characteristics of different welds, and improving the detection capabilities of different weld structures. For complex welding structures or welds with thicker thicknesses, by accurately calculating the exposure conditions, it can be ensured that the image is clear and defects are easy to identify, avoiding missed detection or false detection due to improper settings. By calculating the appropriate exposure and transmission time in advance, it is possible to avoid multiple adjustments to the exposure parameters during the detection process, so that the detection process can be more efficient and the time and cost of readjustment or re-exposure due to inappropriate exposure are reduced.

[0069] Furthermore, the step of obtaining corresponding defect features according to each defect type in step S15, and obtaining weld quality according to multiple defect features, includes:

[0070] S151, obtaining defect features of each defect type, wherein the defect features include defect size features, defect shape features, and defect surface quality features;

[0071] S152, obtaining the defect area according to the defect size characteristics;

[0072] S153, obtaining a defect aspect ratio and a defect roundness according to the defect shape characteristics;

[0073] S154, obtaining defect edge roughness and defect depth according to the defect surface quality characteristics;

[0074] S155. Calculate the defect severity value of the corresponding defect type based on each of the defect area, defect aspect ratio, defect roundness, defect edge roughness, and defect depth, wherein the calculation formula is:

[0075] ;

[0076] in, Indicates the defect degree value, represents the defect area, represents the defect aspect ratio, Indicates the defect roundness, represents the defect edge roughness, Indicates the depth of the defect;

[0077] S156. Obtain a defect weight for each defect degree value, and calculate the weld quality based on the multiple defect degree values ​​and the corresponding defect weights, wherein the calculation formula is:

[0078] ;

[0079] in, Indicates the quality of the weld. Indicates the Defect weights, Indicates the Defect level value, The serial number indicating the defect degree value, Indicates the number of defect degree values.

[0080] As described in the above steps S11-S16, in the present invention, the defect size characteristics, defect shape characteristics and defect surface quality characteristics are obtained from the defect characteristics of each defect type, the defect area is obtained according to the defect size characteristics, the defect aspect ratio and defect roundness are obtained according to the defect shape characteristics, the defect edge roughness and defect depth are obtained according to the defect surface quality characteristics, and the defect degree value of the corresponding defect type is calculated according to each of the defect area, defect aspect ratio, defect roundness, defect edge roughness and defect depth. By measuring the area of ​​the defect, its impact on the overall strength and stability of the weld can be evaluated. A defect with a larger area may mean that the weld has a more serious quality problem, which may lead to a reduction in the structural bearing capacity or a weld fracture. The aspect ratio can reveal the morphological characteristics of the defect. Long strip defects and circular defects may have different effects on the weld. For example, long strip defects may lead to stress concentration, while circular defects may be considered as relatively uniform defects under certain conditions. The roundness feature helps to further judge the nature of the defect. Circular defects are usually simpler, while irregular shapes may be more complex and have a greater impact. Edge roughness and depth can further reflect the severity and potential impact of the defect. For example, a larger defect depth may mean structural damage to the weld, while rough edges may aggravate stress concentration, thereby affecting the fatigue resistance of the weld. Through these multi-dimensional feature analyses, a more comprehensive and accurate assessment of defects in the weld can be made, thereby avoiding the errors or one-sidedness caused by a single indicator. Traditional weld defect assessment often relies on manual visual inspection or experience judgment, and is easily affected by the inspector's The influence of factors such as vision and experience; this method can greatly improve the detection efficiency and accuracy by automatically calculating the specific indicators of defects, and can more accurately determine the impact of different defects on the quality of welds by calculating the degree values ​​of defects. The present invention obtains the defect weight of each defect degree value, and calculates the weld quality according to multiple defect degree values ​​and corresponding defect weights. By assigning a weight value to each defect, it can more accurately quantify the severity of various defects in the weld, and calculate whether the weld meets the requirements of standards and specifications. This calculation method can help automatically determine whether the weld meets the quality standards, reduce human errors, improve consistency and standardization, ensure the quality stability of the weld, ensure that the weld quality meets the requirements of standards and specifications, and ultimately improve the quality and safety of welding products.

[0081] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An energy-saving titanium alloy heat exchanger, characterized by: include: housing (1); An upper tube plate (2) located on the left side of the shell (1); A lower tube plate (3) located on the right side of the shell (1); A slip-on flange (4) is fixed to the shell (1) and is detachable from the upper tube plate (2); A mounting mechanism (5) is located below the housing (1); The upper tube plate (2) is fixedly connected to a pull rod (6) on one side close to the shell (1), and multiple groups of baffles (7) are sequentially installed on the outer side wall of the pull rod (6). A heat exchange tube (9) is welded to the side of the upper tube plate (2) close to the shell (1) through a boss (8), and the heat exchange tube (9) passes through the baffle (7). The lower tube plate (3) is provided with a lower tube hole (10) on one side close to the shell (1), and a guide head (11) is installed inside the lower tube hole (10), and the guide head (11) is detachably connected to the heat exchange tube (9); The mounting mechanism (5) comprises a mounting base (501), a bracket (502), a positioning sleeve (503), a front support plate (504) and a rear support plate (505); the mounting base (501) is provided below the housing (1); two groups of brackets (502) are fixedly connected to the upper surface of the mounting base (501); the brackets (502) are rotatably connected to the positioning sleeve (503) via a first motor (506); the positioning sleeve (503) is in contact with the housing (1); the mounting base (501) is slidably connected to the front support plate (504) and the rear support plate (505) via two groups of adjustment mechanisms (12).

2. The energy-saving titanium alloy heat exchanger according to claim 1, characterized in that: The adjusting mechanism (12) comprises a second motor (1201), a screw rod (1202), a screw block (1203) and an adjusting plate (1204); the upper surface of the mounting base (501) is rotatably connected to the screw rod (1202) via the second motor (1201); the outer wall of the screw rod (1202) is threadedly connected to the screw block (1203); the top end of the screw block (1203) located on one side of the upper tube plate (2) is fixedly connected to the front support plate (504); the screw block (1203) located on one side of the lower tube plate (3) is connected to the rear support plate (505) via an auxiliary mechanism (15). Rotationally connected, the front support plate (504) and the rear support plate (505) are fixedly connected to opposite sides with adjustment plates (1204), an extrusion mechanism (13) is provided above the adjustment plate (1204), the length of the screw (1202) in the adjustment mechanism (12) is adapted to the distance between the upper tube plate (2) and the shell (1), the upper surface of the mounting base (501) is fixedly connected to a limit plate (16), the limit plate (16) is rotationally connected to the screw (1202), and the opposite sides of the front support plate (504) and the rear support plate (505) are fixedly connected to friction pads (17).

3. The energy-saving titanium alloy heat exchanger according to claim 2, characterized in that: The extrusion mechanism (13) comprises a bidirectional telescopic rod (1301), a lifting block (1302), an extrusion block (1303) and a first matching member (1304); the upper portion of the screw block (1203) is slidably connected to the bidirectional telescopic rod (1301) via a slider (1305); both ends of the bidirectional telescopic rod (1301) are fixedly connected to the lifting block (1302); the top end of the bidirectional telescopic rod (1301) is fixedly connected to the extrusion block (1303) via an extension mechanism (14); the first matching member (1304) is rotatably connected between the extrusion block (1303) and the lifting block (1302); the upper surface of the screw block (1203) is fixedly connected to a rotating shaft (1306); and the second matching member (1307) is rotatably connected between the lifting block (1302) and the rotating shaft (1306).

4. The energy-saving titanium alloy heat exchanger according to claim 3, characterized in that: The extension mechanism (14) comprises an extension tube (1401) and an extension rod (1402); the outer wall of the bidirectional telescopic rod (1301) is fixedly connected to the extension tube (1401); the interior of the extension tube (1401) is slidably connected to the extension rod (1402); and the extension rod (1402) is fixedly connected to the extrusion block (1303).

5. The energy-saving titanium alloy heat exchanger according to claim 2, characterized in that: The auxiliary mechanism (15) comprises an extension block (1501) and an extension motor (1502); the front end and the rear end of the screw block (1203) located on one side of the lower tube plate (3) are fixedly connected to the extension block (1501); the extension motor (1502) is embedded in the extension block (1501); the output shaft of the extension motor (1502) is fixedly connected to the rear support plate (505); the side of the rear support plate (505) close to the housing (1) is fixedly connected to the electromagnetic ring (1503); the electromagnetic ring (1503) is electromagnetically attracted to the guide head (11).

6. A method for installing an energy-saving titanium alloy heat exchanger, characterized in that: The energy-saving titanium alloy heat exchanger according to any one of claims 1 to 5 comprises the following steps: S1. Perform radiographic inspection on the weld seam of the shell (1) according to the AD2000 design specification to ensure that the quality of the weld seam meets the standard specification requirements and place the shell (1) between two positioning sleeves (503); S2, by synchronously starting the two sets of second motors (1201), the front support plate (504) and the rear support plate (505) are driven to move relative to each other, the position of the housing (1) is corrected to make it the center point, and then the front support plate (504) and the rear support plate (505) are reset; S3, welding one side of the upper tube plate (2) to the tie rod (6), sequentially installing the baffles (7), and then installing a small number of heat exchange tubes (9) through the bosses (8) for positioning; S4, placing the upper tube plate (2) above the adjustment plate (1204), contacting one side through the front support plate (504), and then contracting the bidirectional telescopic rod (1301) to drive the slider (1305) to move toward the upper tube plate (2), and driving the extrusion block (1303) to rise and contact and extrude with the upper tube plate (2) through the first movable member (1304), inserting the remaining heat exchange tubes (9) into the boss (8) for welding, and then pushing the upper tube plate (2) to the end of the shell (1) through the second motor (1201); S5, rotating the rear support plate (505) by extending the motor (1502), installing the guide head (11) to be magnetically attracted in the electromagnetic ring (1503), and then resetting the rear support plate (505) after calibrating and installing the lower tube plate (3) and the guide head (11), repeating the extrusion mechanism (13), pushing the lower tube plate (3) into the interior of the shell (1) through the adjustment mechanism (12), and engaging the heat exchange tube (9) through the guide head (11), and then guiding it into the lower tube plate (3); S6. Welding the upper tube plate (2) and the lower tube plate (3) to the shell (1), and performing fillet welding on the heat exchange tube (9) and the lower tube plate (3).

7. The method for installing an energy-saving titanium alloy heat exchanger according to claim 6, characterized in that: The step S1 of performing radiographic inspection on the weld of the shell (1) according to the AD2000 design specification comprises: S11. Clean the weld surface, place the X-ray source on one side of the weld, and the digital detector on the opposite side; S12, selecting a suitable radiation transmission time according to the thickness and shape of the weld, and starting exposure according to the radiation transmission time to obtain a digital image of the weld; S13, performing noise removal, contrast enhancement, and brightness adjustment on the digital image of the weld in sequence to obtain a preprocessed weld image; S14, using edge detection technology to analyze and identify the pre-processed weld image to obtain all defect types; S15. Obtain corresponding defect features according to each defect type, and obtain weld quality according to the plurality of defect features; S16, determining whether the weld quality is less than a preset quality; If the weld quality is less than the preset quality, it is determined that the weld quality does not meet the standard specification requirements; If the weld quality is not less than the preset quality, the weld quality is judged to meet the standard specification requirements.

8. The method for installing an energy-saving titanium alloy heat exchanger according to claim 7, characterized in that: The step of selecting a suitable radiation transmission time according to the thickness and shape of the weld in step S12 includes: S121. Obtaining the required exposure and characteristic parameters of the weld, wherein the characteristic parameters include the weld radiation absorption coefficient and the weld thickness; S122. Obtain the initial intensity of the radiation source, and calculate the radiation transmission time according to the required exposure, the initial intensity of the radiation source, the weld radiation absorption coefficient, and the weld thickness.

9. The method for installing an energy-saving titanium alloy heat exchanger according to claim 7, characterized in that: The step of obtaining corresponding defect features according to each defect type in step S15, and obtaining weld quality according to multiple defect features, includes: S151, obtaining defect features of each defect type, wherein the defect features include defect size features, defect shape features, and defect surface quality features; S152, obtaining the defect area according to the defect size characteristics; S153, obtaining a defect aspect ratio and a defect roundness according to the defect shape characteristics; S154, obtaining defect edge roughness and defect depth according to the defect surface quality characteristics; S155, calculating a defect severity value corresponding to the defect type based on each of the defect areas, defect aspect ratios, defect roundness, defect edge roughness, and defect depth; S156. Obtain the defect weight of each defect degree value, and calculate the weld quality based on the multiple defect degree values ​​and corresponding defect weights.

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