Steel penstock derusting device and method

Abstract

The invention discloses a pressure steel pipe derusting device which comprises a roller carrier, a pressure steel pipe derusting device, a pressure steel pipe derusting device and a pressure steel pipe derusting device. The roller carrier is provided with a hydraulic jacking mechanism, and a pair of power roller sets are symmetrically arranged above the roller carrier. And the rust removal assembly comprises a support, an outer wall impeller head and an inner wall impeller head, blasting openings of the outer wall impeller head and the inner wall impeller head face the outer wall of the same part of the pressure steel pipe, and sand blasting materials are fed into a recycling box through recycling mechanisms by recycling openings of the inner wall, the outer wall impeller head and the inner wall impeller head. The invention further discloses a pressure steel pipe rust removal method. The steel pipe shot blasting machine can solve the technical problems that a traditional steel pipe shot blasting machine is low in inner wall and outer wall synchronous treatment efficiency, materials cannot be recycled and the like, is suitable for automatic rust removal operation of pressure steel pipes with different pipe diameters and curvatures, ensures that the surface roughness and cleanliness reach the standard through dynamic parameter cooperative control and real-time quality monitoring, and improves the production efficiency. According to the partition mode, the efficient rust removal effect is achieved for local quality differences.

Description

Technical Field

[0001] The present invention relates to the technical field of water conservancy and hydropower engineering, and more specifically, to a device and method for removing rust from a pressure steel pipe. Background Art

[0002] Penstocks are the core pressure-bearing components of the water transmission and power generation system in water conservancy and hydropower projects. They are exposed to high head, sediment erosion and humid environments for a long time. Oxide layers and rust are easily formed on their surfaces, and rust removal is required to ensure the adhesion of subsequent anti-corrosion coatings. At present, conventional rust removal processes in the industry are mainly divided into two methods: manual sandblasting and mechanical shot blasting, but both have significant technical defects. The manual sandblasting process requires the use of lifting equipment to place the steel pipe flat on a transport trolley. After being transferred to the sandblasting workshop, workers use handheld spray guns to sandblast the surface of the steel pipe section by section. This purely manual sandblasting rust removal method relies solely on the experience of workers and requires sufficient sandblasting personnel, otherwise it will affect the overall steel pipe production progress. The cleanliness and roughness of the pretreatment are difficult to guarantee, the stability is poor, and the re-spraying rate is high, which will cause a waste of resources; temporary scaffolding is used as a construction platform, workers are restricted in operation, and there are safety hazards. The mechanical shot blasting process uses a drum or crawler shot blasting machine to treat the outer wall of the steel pipe. The traditional steel pipe shot blasting machine is used for steel pipe rust removal, and there are technical difficulties such as low efficiency of simultaneous treatment of the inner and outer walls and non-recyclable materials. Especially when using step-by-step shot blasting, the unilateral impact force will cause the steel pipe to produce periodic bending stress, which is easy to deform. In addition, the fixed shot blasting machine roller group spacing and height adjustment range are limited, and it is difficult to adapt to pressure steel pipes with different pipe diameters (such as DN800-DN4000) and curvatures. Therefore, there is an urgent need for a pressure steel pipe processing device that takes into account efficient rust removal, controllable quality, safety and environmental protection, so as to solve systematic technical problems such as high risk of manual operation, poor coordination of mechanical shot blasting and serious waste of resources. Summary of the invention

[0003] The present invention provides a device and method for removing rust from pressure steel pipes, which can solve the technical problems of low efficiency of synchronous processing of inner and outer walls and non-recyclable materials in traditional steel pipe shot blasting machines, and is suitable for automated rust removal operations of pressure steel pipes with different pipe diameters and curvatures. Through dynamic parameter coordinated control and real-time quality monitoring, it can ensure that the surface roughness and cleanliness meet the standards. The zoning mode targets local quality differences and performs efficient rust removal.

[0004] In order to achieve these purposes and other advantages according to the present invention, a penstock rust removal device is provided, comprising: a penstock rust removal device, characterized in that it comprises: A roller frame is slidably mounted on a ground track, and the roller frame has a hydraulic jacking mechanism, and a pair of power roller groups are symmetrically arranged above the hydraulic jacking mechanism to support the pressure steel pipe; A rust removal component comprises a bracket, an outer wall shot blasting machine and an inner wall shot blasting machine, wherein the outer wall shot blasting machine and the inner wall shot blasting machine are fixed to the bracket and extend into a sand blasting workshop, the bracket is provided with a conveying mechanism to convey sand blasting materials to the outer wall shot blasting machine and the inner wall shot blasting machine, the throwing ports of the outer wall shot blasting machine and the inner wall shot blasting machine are respectively directed toward the outer wall and the inner wall of the same part of the penstock, and the recovery ports of the outer wall shot blasting machine and the inner wall shot blasting machine respectively send the sand blasting materials into a recovery box through a recovery mechanism.

[0005] Preferably, it also includes: A dust removal assembly, which includes a dust-proof door curtain provided at the entrance of the sandblasting workshop, and a ventilation mechanism consisting of a surrounding rectangular air suction port, a centrifugal fan and a pulse bag dust collector; The size of the surrounding rectangular air suction port is 500 mm×300 mm, and it is circumferentially arranged around the projection area of ​​the outer wall shot blasting machine and the inner wall shot blasting machine; The air volume of the centrifugal fan is 18,000 m³ / h and the air pressure is 2,500 Pa. Its inlet is connected to the air suction port through a pipe, and its outlet is connected to the pulse bag dust collector. The processing capacity of the pulse bag dust collector is 15,000 m³ / h.

[0006] Preferably, the roller frame comprises: A base, the bottom of which is provided with a sliding portion that slidably cooperates with the ground track; A hydraulic jacking mechanism is vertically installed above the base; A pair of symmetrically arranged power roller groups are installed on the top of the hydraulic jacking mechanism. The power roller group includes a main power roller, an auxiliary power roller and a roller motor driving the two. The main power roller and the auxiliary power roller are mechanically linked and have the same direction of rotation. The speed of the power roller group is the same as the speed of the impeller of the inner and outer wall shot blasting machine, and the direction of rotation is opposite; At least one non-powered roller is disposed between a pair of powered roller groups and is installed at a height lower than the powered roller groups; Among them, the supporting surfaces of the powered roller group and the unpowered roller form a continuous arc-shaped supporting surface, and the curvature radius thereof matches the outer diameter of the pressure steel pipe.

[0007] Preferably, a pair of support seats are provided above the hydraulic jacking mechanism, respectively supporting a pair of power roller groups; The top of each support seat is rotatably connected to the cover body through a transmission shaft, and both ends of the axles of the main power roller and the auxiliary power roller are installed on the cover body through bearings; There are four bearing seats on the jacking mechanism, of which two inner bearing seats are used to mount the driving shaft, and two outer bearing seats are used to mount the driven shaft; The driving shaft is provided with a driving gear, and the driven shaft is provided with a driven gear, and the two driving gears are meshed with each other and respectively meshed with a driven gear on the side; The driven shaft is connected to the transmission shaft through a belt, and one of the driving shafts is driven by a gear motor to synchronously adjust the rotation angle of a pair of power roller groups.

[0008] Preferably, A pair of L-shaped columns are arranged above the jacking mechanism, the horizontal part of which is hinged to the cylinder seat of the cylinder, and the vertical part is rotatably connected to the horizontally arranged adjustment shaft; The adjusting shaft is fixedly connected to a crank arm, one end of the crank arm is hinged to the two ends of the wheel axle of the unpowered roller, and the other end is hinged to the piston rod of the cylinder; The arm section length of the crank arm is configured as follows: when the cylinder piston rod is at the longest stroke, the arm section is horizontal so that a pair of unpowered rollers are positioned at a minimum support height.

[0009] A method for removing rust from a pressure steel pipe, using the pressure steel pipe rust removal device, comprises: Step 1: Steel pipe positioning and stable support: A pair of clamps are installed on the outer periphery of the pressure steel pipe. The distance between the clamps is greater than the length of the power roller group. The height of the pressure steel pipe is adjusted through the hydraulic jacking mechanism of the roller frame, so that the power roller group can accurately support the pipe section between the clamps and inhibit the rotation and deviation of the steel pipe. Step 2: Dynamic parameter collaborative control: Set the impeller speed of the outer wall shot blasting machine and the inner wall shot blasting machine to be equal to the speed of the power roller group, and the impeller direction of the outer wall shot blasting machine and the inner wall shot blasting machine is opposite to that of the power roller group; According to the material and rust grade of the penstock, the sandblasting intensity is adjusted to make the surface roughness reach the predetermined level and meet the adhesion requirements of the epoxy coating; Step 3: Fully enclosed automated operation: Start the power roller group to drive the pressure steel pipe to rotate at a constant speed, and simultaneously start the conveying mechanism to supply abrasive to the shot blasting machine, and realize the recycling of steel sand through the recovery mechanism. Personnel evacuate the workshop throughout the process; The surround suction port captures the projectile dust at a predetermined wind speed and transports it to the pulse bag dust collector.

[0010] Preferably, it also includes: Step 4: Real-time surface quality monitoring: Laser scanning sensors are set near the outer wall shot blasting wheel and the inner wall shot blasting wheel to obtain the point cloud data of the steel pipe surface and construct a three-dimensional model of the pressure steel pipe surface; Extract the axial profile curve, calculate the surface roughness, divide the pressure steel pipe into arc units with equal axial length, identify the surface cleanliness of each arc unit, and set the surface roughness threshold and surface cleanliness threshold; Step 5: Global parameter coordinated adjustment: If the surface roughness of both the inner and outer walls do not meet the standard, increase the rotation speed by 200-300 r / min and the shot flow rate by 20-30 kg / min simultaneously, and repeat the operation until the standard is met. If only the surface roughness of one side wall does not meet the standard, enter the zone dynamic adjustment; Step 6: Dynamic and precise adjustment of partitions: For the side walls that meet the surface roughness standards, identify the surface cleanliness of each arc unit. Surface cleanliness meets the standard: Do not change the rotation speed, and increase the shot flow rate by 30-40 kg / min on the side where the surface roughness does not meet the standard, and reduce the shot flow rate by 20-30 kg / min on the side where the surface roughness meets the standard; Surface cleanliness does not meet the standard: the rotation speed is increased by 100-200 r / min, and the shot flow rate on the side where the surface roughness does not meet the standard is increased by 20-30 kg / min, and the shot flow rate on the side where the surface roughness meets the standard is increased by 10-15 kg / min.

[0011] Preferably, the processed data points are triangulated using a Delaunay triangulation algorithm to generate a number of triangular facets, which are connected to form a preliminary three-dimensional surface model of the penstock, and then the NURBS surface fitting algorithm is used to further optimize the preliminary three-dimensional surface model. By adjusting the parameters of the surface, the surface is made close to the actual surface shape of the penstock, thereby obtaining a three-dimensional surface model of the penstock.

[0012] The present invention has at least the following beneficial effects: In view of the problems of low rust removal efficiency, asynchronous treatment of inner and outer walls, and serious dust pollution in the prior art of pressure steel pipes, the present invention proposes a device integrating a roller frame, inner and outer wall shot blasters, and a dust removal component. The device includes a roller frame slidably mounted on a ground track, and its lifting mechanism supports a pair of power roller groups to drive the steel pipe to rotate; the rust removal component simultaneously performs shot blasting treatment on the inner and outer walls of the steel pipe through the outer wall shot blaster and the inner wall shot blaster, and is equipped with a conveying mechanism and a recovery box to realize the recycling of steel sand. The matching dust removal component realizes efficient dust collection through a surround air suction port, a centrifugal fan, and a pulse bag dust collector.

[0013] The present invention uses the clamp and roller group to clamp the steel pipe in coordination, eliminating the influence of bending deformation, and hydraulic jacking to accurately adjust the working height. The inner and outer wall processing can be completed in a single clamping, reducing the time-consuming repeated positioning. The speed and direction of the inner and outer shot blasters and the roller group are matched in real time, and the vibration is suppressed by the reverse friction torque. The surface roughness and cleanliness are ensured to meet the standards through dynamic parameter coordinated control and real-time quality monitoring; the partition mode reduces the flow rate on the standard side (saving 20-30% of abrasive) and strengthens the impact on the non-standard side to achieve accurate resource allocation, which is suitable for the automated rust removal of large steel pipes.

[0014] Other advantages, objectives and features of the present invention will be embodied in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a structural schematic diagram of a technical solution of the present invention; Figure 2 A schematic diagram of the structure of a roller frame according to a technical solution of the present invention; Figure 3 For the present invention Figure 2 An enlarged schematic diagram of A in FIG. Figure 4 A schematic diagram of adjusting the inclination angle of a roller group according to a technical solution of the present invention; Figure 5 A schematic diagram of height adjustment of an unpowered roller according to a technical solution of the present invention. DETAILED DESCRIPTION

[0016] The present invention is further described in detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0017] It should be understood that terms such as “having”, “including” and “comprising” used herein do not exclude the existence or addition of one or more other elements or combinations thereof.

[0018] It should be noted that the experimental methods described in the following embodiments are conventional methods unless otherwise specified, and the reagents and materials can be obtained from commercial sources unless otherwise specified; in the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected, set, or detachably connected, set, or connected and set in one piece. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood in specific circumstances. The orientation or position relationship indicated by the terms "lateral", "longitudinal", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc. is based on the orientation or position relationship shown in the accompanying drawings, which is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention.

[0019] like Figure 1 As shown, the present invention provides a penstock rust removal device, comprising: The roller frame (1) is slidably mounted on the ground track and can be engaged with the ground track by installing a slider at the bottom. The roller frame (1) has a hydraulic lifting mechanism with a stroke of 0-500 mm to adjust the height of the power roller group. A pair of power roller groups are symmetrically arranged above the hydraulic lifting mechanism to support the pressure steel pipe (2). The power roller groups are driven by two 15 kW motors with a rotation speed of 0-30 r / min. A rust removal component comprises a bracket (3), an outer wall shot blasting machine (4), and an inner wall shot blasting machine (5). The bracket (3) adopts an H-shaped steel welded frame. The outer wall shot blasting machine (4) and the inner wall shot blasting machine (5) are fixed to the bracket (3) and extend into a sandblasting workshop (20). The bracket (3) is provided with a conveying mechanism (6) for conveying sandblasting materials to the outer wall shot blasting machine (4) and the inner wall shot blasting machine (5). The ejection ports of the outer wall shot blasting machine (4) and the inner wall shot blasting machine (5) are respectively oriented toward the outer wall and the inner wall of the same part of the pressure steel pipe (2). In one embodiment, the outer wall shot blasting machine (4) (impeller diameter 400 mm, power 22 kW) and the inner wall shot blasting machine (5) (impeller diameter 250 mm, power 18 kW) are arranged symmetrically at 180°, the ejection port axis is at an angle of 45° with the radial direction of the steel pipe, and the shot flow rate is controlled by an electromagnetic valve (0-100 kg / min), the recovery ports of the outer wall shot blasting machine (4) and the inner wall shot blasting machine (5) respectively send the sandblasting materials into the recovery box (8) through the recovery mechanism (7), and the steel sand after the blasting is collected by the V-shaped guide plate to the screw conveyor, and then returned to the sand storage box for recycling after magnetic separation and screening.

[0020] In the above technical solution, the hydraulic lifting mechanism lifts the pressure steel pipe (2) to the support position of the power roller group, and the motor drives the steel pipe to rotate at a constant speed (10-20 r / min). The outer wall shot blaster (4) and the inner wall shot blaster (5) simultaneously spray steel grit, which impacts the rust layer on the inner and outer walls and is recovered through the guide plate. The synchronous treatment of the inner and outer walls shortens the rust removal time of a single steel pipe by 50%; the closed-loop recovery system reduces the loss of steel grit, the shot blasting coverage rate is ≥98%, and the surface cleanliness reaches Sa2.5 level, which solves the technical problems of traditional steel pipe shot blasting machines in terms of low efficiency of synchronous treatment of the inner and outer walls and non-recyclable materials.

[0021] In another technical solution, it also includes: A dust removal assembly, comprising a dust-proof door curtain (19) arranged at the entrance of a sandblasting workshop (20), and a ventilation mechanism consisting of a surrounding rectangular air suction port, a centrifugal fan and a pulse bag dust collector, wherein the dust-proof door curtain (19) may be a double-layer PVC soft curtain with an intermediate layer filled with activated carbon fibers; The size of the surrounding rectangular air suction port is 500 mm×300 mm, and it is arranged circumferentially around the projection area of ​​the outer wall shot blaster (4) and the inner wall shot blaster (5). A group of the air suction ports is arranged at intervals of 1.5 meters along the axial direction of the steel pipe. Each group contains 4 air suction ports, and the wind speed is controlled to be 12-15 m / s, so as to achieve "source capture" of the dust generation point; The air volume of the centrifugal fan is 18,000 m³ / h and the air pressure is 2,500 Pa. Its inlet is connected to the air suction port through a pipe, and its outlet is connected to the pulse bag dust collector. The processing capacity of the pulse bag dust collector is 15,000 m³ / h.

[0022] In the above technical solution, the dusty airflow generated by shot blasting is captured by the negative pressure of the air suction port, and enters the pulse bag dust collector after being pressurized by the centrifugal fan. The emission concentration of the purified gas is ≤10 mg / m³, and the steel sand powder is collected centrally by the spiral ash conveyor. The PM10 concentration in the workshop can be reduced from 200 mg / m³ to below 15 mg / m³, solving the technical problem that most shot blasting machines only use soft curtains or local air suction ports (such as single-side exhaust on the top), and dust is easily dissipated from the inlet and outlet of the steel pipe.

[0023] like Figure 2-3 As shown, in another technical solution, the roller frame (1) comprises: A base, the bottom of which is provided with a sliding portion that slidably cooperates with the ground track; The hydraulic lifting mechanism may adopt a double-acting hydraulic cylinder and be installed vertically above the base; A pair of symmetrically arranged power roller groups are installed on the top of the hydraulic jacking mechanism. The power roller group comprises a main power roller (9), an auxiliary power roller (10) and a roller motor driving the main power roller (9) and the auxiliary power roller (10). The main power roller (9) and the auxiliary power roller (10) are driven by a synchronous belt. The surfaces of the rollers are coated with a polyurethane layer. The main power roller (9) and the auxiliary power roller (10) are mechanically linked and have the same direction of rotation. The rotation speed of the power roller group is the same as the rotation speed of the impellers of the inner and outer wall shot blasting machines (4), but the rotation direction is opposite. At least one unpowered roller (11) is arranged between a pair of powered roller groups and is installed at a height lower than the powered roller group. The unpowered roller (11) is installed at a height 30-50 mm lower than the powered roller group. The spacing can be adjusted by driving a crank arm (18) via a cylinder (17); The supporting surfaces of the powered roller group and the unpowered roller (11) form a continuous arc-shaped supporting surface, the radius of curvature of which matches the outer diameter of the pressure steel pipe (2).

[0024] In the above technical solution, the hydraulic lifting mechanism adjusts the height of the power roller assembly according to the diameter of the pressure steel pipe (2) (e.g., DN1200) so that the curvature radius of the arc-shaped supporting surface matches the outer diameter of the steel pipe (R=600 mm). The non-powered roller (11) is adjusted in spacing by the cylinder (17) to form a three-point support to suppress radial runout, thus solving the technical problem that the traditional roller assembly cannot adapt to steel pipes of different diameters and the curvature deviation of the supporting surface causes rotational deviation.

[0025] like Figure 4 As shown, in another technical solution, a pair of support seats (12) are provided above the hydraulic jacking mechanism. The support seats (12) can be triangular column-shaped supports, each supporting a pair of power roller groups. A damping layer is provided inside the support seat (12) to absorb high-frequency vibrations. The top of each support seat (12) is rotatably connected to the cover body (13) via a transmission shaft. The transmission shaft and the cover body (13) are spline-connected, allowing the transmission shaft and the cover body (13) to rotate relative to each other within a set angle range, thereby meeting the requirements for adjusting the inclination angle of the roller group. Both ends of the axles of the main power roller (9) and the auxiliary power roller (10) are mounted on the cover body (13) via bearings, thereby providing a degree of freedom for angle adjustment while ensuring rigidity. There are four bearing seats on the jacking mechanism, of which two inner bearing seats are used to mount the driving shaft, and two outer bearing seats are used to mount the driven shaft; The driving shaft is provided with a driving gear (14), and the driven shaft is provided with a driven gear (16); the two driving gears (14) mesh with each other and respectively mesh with a driven gear (16) on the side; the driving gear (14) and the driven gear (16) achieve torque distribution through meshing transmission, thereby ensuring symmetry of power output of the roller groups on both sides; The driven shaft is connected to the transmission shaft through a belt, and the belt preload is controlled at 120-150 N by a tensioning pulley. One of the driving shafts is driven by a gear motor to synchronously adjust the rotation angle of a pair of power roller groups.

[0026] In the above technical solution, the gear motor drives the driving shaft to rotate, drives the driving gear (14) to mesh, and synchronously drives the driven gears (16) on both sides to rotate; the driven shaft transmits power to the transmission shaft through the belt, drives the cover (13) to rotate around the support seat (12), thereby adjusting the angle of the power roller group. The meshing of the driving gear (14) ensures that the inclination angles of the roller groups on both sides change synchronously, and the belt transmission compensates for the installation error. When the angle of the roller group is adjusted to match the outer diameter of the steel pipe, the powered roller and the unpowered roller (11) form a continuous arc-shaped support surface, the hydraulic jacking mechanism lifts the steel pipe to the working height, and the motor drives the roller to rotate at a constant speed, so as to achieve the synchronization of stable self-rotation of the steel pipe and shot blasting. The gear-belt linkage design takes into account both the angle adjustment accuracy and the transmission stability, and solves the technical problem that the angle adjustment of the roller group of the traditional roller frame (1) relies on manual operation, which easily leads to the inclination angles of the rollers on both sides being asynchronous, low adjustment efficiency and poor stability.

[0027] like Figure 5 As shown, in another technical solution, a pair of L-shaped columns (15) are provided above the jacking mechanism, the horizontal portion of which is hinged to the cylinder seat of the cylinder (17), and the vertical portion is rotatably connected to the horizontally arranged adjustment shaft; a pair of mounting plates can be provided at the top of the vertical portion to horizontally mount the adjustment shaft, ensuring that the rotation of the adjustment shaft has space for the crank arm (18) to move, and the piston rod of the cylinder (17) is connected to the unpowered roller (11) through the crank arm (18) mechanism, thereby amplifying the driving force by utilizing the lever principle; The adjusting shaft is fixedly connected to a crank arm (18), which is L-shaped. One end of the crank arm (18) is hinged to the two ends of the wheel axle of the unpowered roller (11), and the other end is hinged to the piston rod of the cylinder (17); The arm section length of the crank arm (18) is configured such that when the piston rod of the cylinder (17) is at the longest stroke, the arm section is horizontal so that a pair of unpowered rollers (11) are spaced and positioned at the lowest support height.

[0028] In the above technical solution, when the piston rod of the cylinder (17) is extended or retracted, the crank arm (18) is driven to rotate around the adjustment axis, driving the unpowered roller (11) to rise or fall. When the piston rod is fully extended (maximum stroke), the crank arm (18) is in a horizontal state, and the unpowered roller (11) is lowered to the lowest support height, forming a stepped support surface with the power roller group; when the piston rod is retracted, the crank arm (18) is swung upward, the unpowered roller (11) is lifted, and the hydraulic jacking mechanism synchronously adjusts the height so that the curvature of the arc-shaped support surface formed by the three groups of rollers matches the outer diameter of the steel pipe. The L-shaped column (15) absorbs the thrust of the cylinder (17) through the hinge point, and the adjustment axis converts the rotational motion into the vertical displacement of the unpowered roller (11), thereby realizing adaptive adjustment of the support height. The system ensures that there is no offset vibration when the steel pipe rotates through mechanical linkage and hydraulic coordination, solving the technical problem that the fixed unpowered roller (11) cannot adapt to steel pipes of different diameters, resulting in discontinuous curvature of the support surface and causing vibration of the steel pipe.

[0029] A method for removing rust from a pressure steel pipe, using the pressure steel pipe rust removal device, comprises: Step 1: Steel pipe positioning and stable support: A pair of clamps are installed on the outer circumference of the pressure steel pipe (2), and the spacing between the clamps is greater than the length of the power roller group, that is, the pipe length between the pair of clamps is slightly greater than the length of the pair of power roller groups. The height of the pressure steel pipe (2) is adjusted by the hydraulic jacking mechanism of the roller frame (1), so that the power roller group accurately supports the pipe section between the clamps, suppresses the rotation deviation of the steel pipe, and solves the problem of support instability caused by bending and elliptical deformation of the steel pipe in the traditional process. The roller frame (1) travels to the inside of the sandblasting workshop (20), so that the pipe wall of the pressure steel pipe (2) is located between the ejection ports of the outer wall shot blasting machine (4) and the inner wall shot blasting machine (5), forming an internal and external synchronous shot blasting operation space, and eliminating repeated positioning errors caused by step-by-step processing; Step 2: Dynamic parameter collaborative control: The impeller speeds of the outer wall shot blasting machine (4) and the inner wall shot blasting machine (5) are set to be equal to the speed of the power roller group, and the impellers of the outer wall shot blasting machine (4) and the inner wall shot blasting machine (5) are turned in the opposite direction to the power roller group, so as to suppress the vibration of the steel pipe through the reverse friction torque and solve the problem of uneven shot blasting coverage; According to the material and rust level of the penstock (2), the sandblasting intensity is adjusted so that the surface roughness reaches the predetermined level Ry60~100μm (Sa2.5 level) and meets the adhesion requirements of the epoxy coating; Step 3: Fully enclosed automated operation: The power roller group is started to drive the pressure steel pipe (2) to rotate at a constant speed, and the conveying mechanism (6) is simultaneously started to supply abrasive to the shot blasting machine, and the steel sand is recycled through the recovery mechanism (7). Personnel are evacuated from the workshop during the whole process to avoid the risk of dust exposure caused by manual intervention, and the steel pipe sandblasting and rust removal operation is carried out; The surround suction port captures the projectile dust at a predetermined wind speed and transports it to the pulse bag dust collector, which performs dust removal operations at the same time.

[0030] In the above technical solution, the three-in-one design of clamp positioning-parameter coordination-enclosed dust removal systematically solves the technical problems of deformation out of control, low efficiency, environmental pollution, coating failure, etc. in the rust removal of pressure steel pipe (2). The clamp-roller group synergistically supports and suppresses the rotation deviation of the steel pipe, avoiding the deviation of the shot blasting trajectory. Through the synchronous operation of the internal and external shot blasting machines, the internal and external surfaces of the steel pipe can be treated by a single clamping. Compared with the traditional step-by-step process, the repeated positioning error is reduced, and the construction period is significantly shortened. The fully enclosed workshop and automatic dust removal system make the dust concentration in the working environment ≤10mg / m³, eliminating the risk of artificial exposure. The internal and external shot blasting machines have a dynamic matching mechanism of speed / steering to avoid deformation of the steel pipe caused by unilateral impact. The steel grit recovery rate is increased from the traditional 50% to 92%, saving more than 30% of the abrasive cost annually.

[0031] In another technical solution, it also includes: Step 4: Real-time surface quality monitoring: A laser scanning sensor is arranged near the outer wall shot blasting wheel (4) and the inner wall shot blasting wheel (5), with a measurement accuracy of ±0.05 mm and a scanning frequency of 1000 Hz. Point cloud data of the steel pipe surface is obtained by multi-angle line laser scanning, and data filtering and denoising are performed, data registration is performed, and redundant data is removed to obtain key point cloud data. The discrete point cloud is converted into a continuous triangular mesh based on the Delaunay triangulation algorithm, and then a three-dimensional model of the surface of the pressure steel pipe (2) is constructed by the NURBS surface fitting technology to accurately restore the surface micro-morphology; Extracting the axial contour curve, using a wavelet transform algorithm to separate the surface waviness and roughness components, respectively calculating the arithmetic mean deviation Ra and the maximum height Rz of the outer wall contour and the inner wall contour, calculating the surface roughness, dividing the pressure steel pipe (2) into arc units of equal axial length, identifying the residual area ratio of oxide scale in each unit based on image segmentation technology, specifically, setting a reflection intensity threshold and a color threshold for distinguishing between the rusted part and the clean part, counting the area of ​​the region below the reflection intensity threshold and the color threshold, traversing the point cloud data, judging whether the point belongs to the rusted area or the clean area according to the set threshold, counting the number of points of the rusted area and the clean area of ​​the outer wall and the inner wall of each arc unit, calculating the surface cleanliness of the outer wall and the inner wall of each arc unit, thereby identifying the surface cleanliness of each arc unit, and setting a surface roughness threshold and a surface cleanliness threshold; Step 5: Global parameter coordinated adjustment: If the surface roughness of both the inner and outer walls do not meet the standard, it is determined that the systematic treatment intensity is insufficient, and the global control mode is triggered - the impeller speed and the shot flow rate of the shot blasting machine are increased synchronously, and the speed is increased by 200-300 r / min and the shot flow rate is increased by 20-30 kg / min. Repeat the operation until the standard is met, and the surface is uniformly strengthened by enhancing the impact energy per unit area. If only the surface roughness of a single side wall does not meet the standard, it is determined that the local process parameters are mismatched, and the system automatically switches to the partition adjustment mode and enters the partition dynamic adjustment. Asymmetric resource allocation is implemented for the defective side to avoid energy waste caused by global parameter adjustment; Step 6: Dynamic and precise adjustment of partitions: For the side walls that meet the surface roughness standards, identify the surface cleanliness of each arc unit. Surface cleanliness meets the standard: reduce the shot flow rate on the side that meets the standard to reduce ineffective impact, and significantly increase the shot flow rate on the side that does not meet the standard, forming a resource tilting strategy of "suppressing the strong and supplementing the weak", that is, without changing the rotation speed, and increase the shot flow rate on the side where the surface roughness does not meet the standard by 30-40 kg / min, and reduce the shot flow rate on the side where the surface roughness meets the standard by 20-30 kg / min; Surface cleanliness does not meet the standard: Synergistically increase the rotation speed and flow rate on both sides, and thoroughly remove the deep oxide scale by increasing the kinetic energy input intensity. At the same time, slightly increase the flow rate on the standard side to compensate for the loss of coverage caused by the increase in rotation speed. That is, the rotation speed is simultaneously increased by 100-200 r / min, and the shot flow rate on the side where the surface roughness does not meet the standard is increased by 20-30 kg / min, and the shot flow rate on the side where the surface roughness meets the standard is increased by 10-15 kg / min.

[0032] This technical solution achieves real-time control and dynamic optimization of the rust removal quality of the pressure steel pipe (2) through the following mechanisms: Digital modeling of surface quality: Use laser scanning sensors to obtain three-dimensional point cloud data on the steel pipe surface, and generate a high-precision surface model through a geometric reconstruction algorithm. The model is divided into equal-length arc units along the axial direction, and the contour curves of each unit are extracted respectively. The surface roughness and surface cleanliness indicators are calculated and compared with the preset threshold to locate the quality defect area.

[0033] Hierarchical control strategy: Global coordinated adjustment: When the overall quality of the inner and outer walls does not meet the standards, the system will simultaneously increase the speed of the shot blasting machine and the flow rate of the projectiles to achieve uniform strengthening treatment by enhancing the impact energy; Dynamic adaptation of partitions: If only one side does not meet the standard, the system enters the partition mode: for units with roughness that meet the standard but insufficient cleanliness, the rotation speed is maintained and the shot flow rate is adjusted differentially to avoid over-throwing; for units with both cleanliness and roughness defects, the rotation speed and flow rate are collaboratively increased to ensure that the defects are eradicated.

[0034] Asymmetric resource allocation: For local defective units, the system dynamically allocates shot blasting resources: the shot flow rate is reduced on the side that meets the standard to save abrasive, while the impact strength is specifically enhanced on the side that does not meet the standard; When the cleanliness level does not meet the standard, the system increases the rotation speed while increasing the supply of projectiles toward the non-standard side, forming a "high-intensity focusing" effect, with only a slight increase on the standard side, balancing processing efficiency and losses.

[0035] In the above technical solution, a closed-loop quality control system of "detection-analysis-execution" is constructed through real-time three-dimensional modeling and dynamic hierarchical regulation. Laser scanning accurately quantifies the surface morphology, decouples the surface roughness and surface cleanliness indicators into independent thresholds, and realizes the refined positioning of quality defects; global parameter adjustment simultaneously strengthens the shot blasting intensity for overall quality defects, while zoning regulation implements an asymmetric strategy based on local quality differences: for areas with qualified roughness but insufficient cleanliness, the rotation speed is maintained and the shot flow rate is differentially regulated to avoid over-blasting; for areas with both cleanliness and roughness defects, the rotation speed and flow rate are collaboratively improved to ensure that defects are eradicated. This solution breaks through the limitations of traditional homogenization processing. Through multi-dimensional threshold judgment and dynamic resource allocation, while ensuring quality consistency, it significantly reduces the abrasive loss and equipment wear caused by redundant shot blasting, and promotes the upgrade of rust removal technology to intelligence and adaptability.

[0036] In another technical solution, the processed data points are triangulated using the Delaunay triangulation algorithm to generate a number of triangular facets. The minimum internal angle of the mesh is maximized by the empty circle criterion (i.e., the circumscribed circle of each triangle does not contain other points) to avoid generating narrow and long triangles. The preliminary three-dimensional model of the surface of the pressure steel pipe (2) is formed by connecting them. For the hole area, constrained Delaunay triangulation (CDT) is introduced, and the boundary feature lines are used as constraint edges to forcibly retain geometric continuity to ensure that the mesh of the hole area is seamlessly connected with the overall topological structure. Then, based on the preliminary triangular mesh, control points, node vectors and weight parameters are extracted to construct an initial NURBS surface. The NURBS surface fitting algorithm is used, and the least squares fitting algorithm is used to optimize the control point coordinates and weights to make the surface close to the measured point cloud. , where S(u,v) is the NURBS surface equation, Pi is the measured point cloud, and λ is the smoothness weight coefficient; the preliminary three-dimensional surface model is further optimized by adjusting the surface parameters, and for local areas with sudden changes in curvature (such as welds and corrosion pits), the parametric freedom is improved through node insertion and subdivision operations to achieve high-precision geometric fitting, so that the surface is close to the actual surface shape of the pressure steel pipe (2), and the three-dimensional surface model of the pressure steel pipe is obtained.

[0037] In the above technical solution, a high-precision and high-stability three-dimensional geometric model is constructed through the synergy of discrete point cloud triangulation and NURBS surface parametric optimization. Delaunay triangulation avoids narrow and long mesh defects and ensures the topological stability of the model; constrained triangulation retains the geometric continuity of the hole area and provides a complete expression for complex surface features. NURBS surface optimization combines least squares fitting with local curvature adaptive subdivision. While globally approximating the actual morphology, it achieves a leap in local accuracy for sudden changes such as welds and corrosion pits. The model iteration verification mechanism ensures the consistency of the three-dimensional model with the real surface through dynamic correction of geometric deviations, providing a reliable geometric basis for engineering applications such as stress distribution analysis and coating uniformity simulation. This method breaks through the bottleneck of traditional modeling technology in expressing the surface features of complex industrial components, and significantly improves the accuracy and reliability of engineering analysis.

[0038] The number of devices and processing scales described here are used to simplify the description of the present invention. Applications, modifications and variations of the present invention will be obvious to those skilled in the art.

[0039] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the implementation modes, and they can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A penstock rust removal device, characterized in that: include: A roller frame is slidably mounted on a ground track, and the roller frame has a hydraulic jacking mechanism, and a pair of power roller groups are symmetrically arranged above the hydraulic jacking mechanism to support the pressure steel pipe; A rust removal component comprises a bracket, an outer wall shot blasting machine and an inner wall shot blasting machine, wherein the outer wall shot blasting machine and the inner wall shot blasting machine are fixed to the bracket and extend into a sand blasting workshop, the bracket is provided with a conveying mechanism to convey sand blasting materials to the outer wall shot blasting machine and the inner wall shot blasting machine, the throwing ports of the outer wall shot blasting machine and the inner wall shot blasting machine are respectively directed toward the outer wall and the inner wall of the same part of the penstock, and the recovery ports of the outer wall shot blasting machine and the inner wall shot blasting machine respectively send the sand blasting materials into a recovery box through a recovery mechanism.

2. The penstock rust removal device according to claim 1, characterized in that: Also includes: A dust removal assembly, which includes a dust-proof door curtain provided at the entrance of the sandblasting workshop, and a ventilation mechanism consisting of a surrounding rectangular air suction port, a centrifugal fan and a pulse bag dust collector; The size of the surrounding rectangular air suction port is 500 mm×300 mm, and it is circumferentially arranged around the projection area of ​​the outer wall shot blasting machine and the inner wall shot blasting machine; The air volume of the centrifugal fan is 18,000 m³ / h and the air pressure is 2,500 Pa. Its inlet is connected to the air suction port through a pipe, and its outlet is connected to the pulse bag dust collector. The processing capacity of the pulse bag dust collector is 15,000 m³ / h.

3. The penstock rust removal device according to claim 1, characterized in that: The roller frame comprises: A base, the bottom of which is provided with a sliding portion that slidably cooperates with the ground track; A hydraulic jacking mechanism is vertically installed above the base; A pair of symmetrically arranged power roller groups are installed on the top of the hydraulic jacking mechanism. The power roller group includes a main power roller, an auxiliary power roller and a roller motor driving the two. The main power roller and the auxiliary power roller are mechanically linked and have the same direction of rotation. The speed of the power roller group is the same as the speed of the impeller of the inner and outer wall shot blasting machine, and the direction of rotation is opposite; At least one non-powered roller is disposed between a pair of powered roller groups and is installed at a height lower than the powered roller groups; Among them, the supporting surfaces of the powered roller group and the unpowered roller form a continuous arc-shaped supporting surface, and the curvature radius thereof matches the outer diameter of the pressure steel pipe.

4. The penstock rust removal device according to claim 3, characterized in that: A pair of support seats are provided above the hydraulic jacking mechanism, each supporting a pair of power roller groups; The top of each support seat is rotatably connected to the cover body through a transmission shaft, and both ends of the axles of the main power roller and the auxiliary power roller are installed on the cover body through bearings; There are four bearing seats on the jacking mechanism, of which two inner bearing seats are used to mount the driving shaft, and two outer bearing seats are used to mount the driven shaft; The driving shaft is provided with a driving gear, and the driven shaft is provided with a driven gear, and the two driving gears are meshed with each other and respectively meshed with a driven gear on the side; The driven shaft is connected to the transmission shaft through a belt, and one of the driving shafts is driven by a gear motor to synchronously adjust the rotation angle of a pair of power roller groups.

5. The penstock rust removal device according to claim 3, characterized in that: A pair of L-shaped columns are arranged above the jacking mechanism, the horizontal part of which is hinged to the cylinder seat of the cylinder, and the vertical part is rotatably connected to the horizontally arranged adjustment shaft; The adjusting shaft is fixedly connected to a crank arm, one end of the crank arm is hinged to the two ends of the wheel axle of the unpowered roller, and the other end is hinged to the piston rod of the cylinder; The arm section length of the crank arm is configured as follows: when the cylinder piston rod is at the longest stroke, the arm section is horizontal so that a pair of unpowered rollers are positioned at a minimum support height.

6. A method for removing rust from a pressure steel pipe, characterized in that: The penstock rust removal device according to any one of claims 1 to 5 comprises: Step 1: Steel pipe positioning and stable support: A pair of clamps are installed on the outer periphery of the pressure steel pipe. The distance between the clamps is greater than the length of the power roller group. The height of the pressure steel pipe is adjusted through the hydraulic jacking mechanism of the roller frame, so that the power roller group can accurately support the pipe section between the clamps and inhibit the rotation and deviation of the steel pipe. Step 2: Dynamic parameter collaborative control: Set the impeller speed of the outer wall shot blasting machine and the inner wall shot blasting machine to be equal to the speed of the power roller group, and the impeller direction of the outer wall shot blasting machine and the inner wall shot blasting machine is opposite to that of the power roller group; According to the material and rust grade of the penstock, the sandblasting intensity is adjusted to make the surface roughness reach the predetermined level and meet the adhesion requirements of the epoxy coating; Step 3: Fully enclosed automated operation: Start the power roller group to drive the pressure steel pipe to rotate at a constant speed, and simultaneously start the conveying mechanism to supply abrasive to the shot blasting machine, and realize the recycling of steel sand through the recovery mechanism. Personnel evacuate the workshop throughout the process; The surround suction port captures the projectile dust at a predetermined wind speed and transports it to the pulse bag dust collector.

7. The method for derusting a pressure steel pipe according to claim 6, characterized in that: Also includes: Step 4: Real-time surface quality monitoring: Laser scanning sensors are set near the outer wall shot blasting wheel and the inner wall shot blasting wheel to obtain the point cloud data of the steel pipe surface and construct a three-dimensional model of the pressure steel pipe surface; Extract the axial profile curve, calculate the surface roughness, divide the pressure steel pipe into arc units with equal axial length, identify the surface cleanliness of each arc unit, and set the surface roughness threshold and surface cleanliness threshold; Step 5: Global parameter coordinated adjustment: If the surface roughness of both the inner and outer walls do not meet the standard, increase the rotation speed by 200-300 r / min and the shot flow rate by 20-30 kg / min simultaneously, and repeat the operation until the standard is met. If only the surface roughness of one side wall does not meet the standard, enter the zone dynamic adjustment; Step 6: Dynamic and precise adjustment of partitions: For the side walls that meet the surface roughness standards, identify the surface cleanliness of each arc unit. Surface cleanliness meets the standard: Do not change the rotation speed, and increase the shot flow rate by 30-40 kg / min on the side where the surface roughness does not meet the standard, and reduce the shot flow rate by 20-30 kg / min on the side where the surface roughness meets the standard; Surface cleanliness does not meet the standard: the rotation speed is increased by 100-200 r / min, and the shot flow rate on the side where the surface roughness does not meet the standard is increased by 20-30 kg / min, and the shot flow rate on the side where the surface roughness meets the standard is increased by 10-15 kg / min.

8. The method for derusting a pressure steel pipe according to claim 7, characterized in that: The Delaunay triangulation algorithm is used to triangulate the processed data points to generate a number of triangular patches, which are connected to form a preliminary three-dimensional surface model of the penstock. The NURBS surface fitting algorithm is then used to further optimize the preliminary three-dimensional surface model. By adjusting the surface parameters, the surface is made close to the actual surface shape of the penstock, and the three-dimensional surface model of the penstock is obtained.

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