Automatic cleaning device for solid phase content detection kettle body and cleaning evaluation method

Abstract

The invention relates to the technical field of solid phase content detection, and discloses a solid phase content detection kettle body automatic cleaning device and a cleaning evaluation method. A laser scanning probe is integrated with a sapphire optical window and a compressed air curtain, the thickness of residues is measured through the peak value of reflected light, the precision is + / -1 micron, and temperature drift is dynamically compensated; an electrostatic adsorption mechanism; rotating the milling cutter mechanism; according to the system, a closed-loop feedback mechanism is adopted to dynamically adjust cleaning parameters (such as spraying pressure, voltage and gas flow), a temperature drift compensation and error correction model is combined, the residue thickness detection precision reaches + / -0.8 [mu] m, quantitative evaluation basis # imgabs0 # # imgabs1 # is provided for cleaning quality, subjective judgment errors are avoided, and the reliability of detection data is remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of solid content detection, and particularly to an automatic cleaning device for a solid content detection kettle body and a cleaning evaluation method. Background Art

[0002] During the solid content detection process, sintered residues often form on the inner wall of the kettle body due to the high-temperature and high-pressure environment. Traditional cleaning methods mainly rely on manual brushing or single mechanical removal, which have problems such as low efficiency, uncontrollable effects, and insufficient adaptability. Manual operation is time-consuming and laborious and difficult to completely remove fine dust, resulting in a long cleaning cycle; at the same time, there is a lack of real-time monitoring means, and the thickness of the residues cannot be quantitatively evaluated, directly affecting the accuracy of subsequent detection data. Existing cleaning devices are difficult to adapt to complex working conditions due to their inability to dynamically adjust parameters such as pressure and temperature, and the cleaning quality fluctuates significantly, further exacerbating process instability.

[0003] In the current technology, although ultrasonic or laser detection means can partially achieve residue monitoring, there are limitations such as insufficient multi-sensor data fusion and lack of an error compensation mechanism. A single detection method is easily affected by the environment, the data reliability is low, and error sources such as temperature drift and electronic noise are not effectively corrected, resulting in limited detection accuracy (the error is usually ≥3u m ). In addition, the traditional cleaning and detection processes are separated, lacking a closed-loop feedback mechanism, and it is difficult to achieve fully automated operation. The evaluation of the cleaning effect mainly relies on manual visual inspection or sampling detection, which is highly subjective and has poor repeatability and cannot meet the requirements of high-precision detection. Therefore, there is an urgent need for a system that integrates automated cleaning, multi-sensor fusion monitoring, and quantitative evaluation to improve the cleaning efficiency and the reliability of detection data.

[0004] For this reason, we propose an automatic cleaning device for a solid content detection kettle body and a cleaning evaluation method. Summary of the Invention

[0005] The present invention mainly solves the technical problems existing in the above-mentioned prior art, and provides an automatic cleaning device for a solid content detection kettle body and a cleaning evaluation method.

[0006] To achieve the above object, the present invention adopts the following technical solutions. An automatic cleaning device for a solid content detection kettle body includes:

[0007] A distributed ultrasonic sensing network, where the sensing network is composed of arrayed piezoelectric ceramic chips (PZT) attached to the outer wall of the detection kettle body, and the vibration mode of the cylinder is excited by 50 kHz low-frequency ultrasonic waves to detect the frequency shift caused by the residues on the inner wall.

[0008] A laser scanning probe, the probe integrates a sapphire optical window and a compressed air curtain, is installed 20 - 50 mm away from the inner wall of the detection kettle body, and measures the thickness of the residues through the peak value of the reflected light, with an accuracy of ±1um , and dynamically compensate for temperature drift;

[0009] The electrostatic adsorption mechanism includes a flexible and telescopic electrostatic adsorption film and a motor M1. The outer diameter of the flexible and telescopic electrostatic adsorption film is slightly smaller than the inner diameter of the detection kettle body, forming a gap of 1 - 1.5 mm with the inner wall. A voltage of 500 - 800 V is applied to adsorb dust. The surface of the flexible and telescopic electrostatic adsorption film is covered with a polytetrafluoroethylene insulating layer and is connected to the grounding terminal of the detection kettle body to prevent arc discharge;

[0010] The rotary milling cutter mechanism includes a milling cutter, an eccentric motor 2, and a horizontal fixed support. The diameter of the milling cutter is 1 / 3 - 2 / 3 of the inner diameter of the detection kettle body, and its up and down movement is controlled by a vertical adjustment track and an adjustment cylinder for cutting large sintered residues;

[0011] The multi - physical - field fusion system fuses laser and ultrasonic data, calculates the thickness of the residue through a weighted average model, with the weight of laser data being 0.5u m , and the weight of ultrasonic data being 3u m , and based on the temperature - drift compensation formula Δd = a s ·ΔT·d raw +β e ·ΔT corrects the measurement error, where d raw is the original laser - measured thickness, ΔT is the temperature change, the thermal expansion coefficient a s of sapphire = 1.2×10 -5 ℃ -1 , and the electron drift coefficient β e = 3×10 -9 ℃ -1 , and the uncertainty after compensation ≤ 0.8u m .

[0012] As a further limitation of the above - mentioned solution, the laser scanning probe is an 8 - probe annular array, with one probe distributed every 45°, and is axially scanned by a robotic arm.

[0013] As a further limitation of the above - mentioned solution, the flexible and telescopic electrostatic adsorption film of the electrostatic adsorption mechanism realizes circumferential rotation through the adjustment cylinder 1 on the top platform, and retracts to the standby position of the vertical cleaning track after cleaning.

[0014] As a further limitation of the above - mentioned solution, the milling cutter is driven by the eccentric motor 2 to rotate at a speed of 100 - 300 rpm, and there are air holes on the top of the milling cutter to support local purging with high - pressure gas of 0.5 - 1.0 MPa.

[0015] As a further limitation of the above solution, the spatio-temporal registration algorithm of the multi-physical field fusion system includes constructing a unified coordinate system (Z-axis, θ angle, radial R), mapping the laser polar angle data to the ultrasonic grid through polar coordinate transformation, aligning the data points using the bilinear interpolation method, and constraining the registration error ≤ ±0.5 mm.

[0016] A cleaning evaluation method for an automatic cleaning device of a solid content detection kettle body includes the above automatic cleaning device of the solid content detection kettle body, and specifically includes the following steps:

[0017] Step 1: Initial cleaning stage, cutting large sintered residues through a rotary milling cutter;

[0018] Step 2: Multi-sensor detection stage, fusing laser and ultrasonic data to calculate the thickness of the residues;

[0019] Step 3: Fine cleaning stage, starting the electrostatic adsorption mechanism to remove dust according to the detection results;

[0020] Step 4: Cycle verification stage, the calculation formula of the cleanliness index (CDI): where D threshold = 20u m is the residue threshold. If the residue thickness exceeds 20u m , then repeat the fine cleaning and conduct high-pressure gas purging through the top air holes of the milling cutter (5), the gas pressure is 0.5 - 1.0 MPa, the purging path is corrected in real time by the D final distribution, and the purging time ≤ 30 seconds until CDI ≥ 95%, and the residue thickness meets the standard.

[0021] As a preferred technical solution of the present invention, the air flow direction of the high-pressure gas purging is precisely aligned with the residue distribution area, and the purging path is corrected in real time by the detection data.

[0022] The present invention provides an automatic cleaning device for a solid content detection kettle body and a cleaning evaluation method. It has the following beneficial effects:

[0023] Through the staged automatic cleaning process (initial cleaning, fine cleaning, high-pressure purging) and multi-sensor fusion detection (weighted fusion of laser and ultrasonic data), the cleaning efficiency is significantly improved, the cleaning cycle is shortened by more than 50%, and the residue removal rate ≥ 99%, solving the problems of low efficiency and uncontrollable effect of traditional manual cleaning.

[0024] 2. The automatic cleaning device for a solid content detection kettle body and the cleaning evaluation method adopt a closed-loop feedback mechanism to dynamically adjust cleaning parameters (such as spray pressure, voltage, gas flow rate), combined with temperature drift compensation and error correction model, and the residue thickness detection accuracy reaches ±0.8u m, providing a quantitative evaluation basis for cleaning quality (cleanliness index CDI), avoiding subjective judgment errors, and significantly improving the reliability of detection data.

[0025] 3. The automatic cleaning device and cleaning evaluation method for the solid content detection kettle body are modularly designed (ultrasonic sensing network, laser probe, electrostatic adsorption mechanism), which supports rapid maintenance and function expansion, reduces the use cost, and is suitable for long-term stable operation in scenarios such as laboratories and chemical production.

[0026] 4. The automatic cleaning device and cleaning evaluation method for the solid content detection kettle body can cope with working conditions such as high temperature and high pressure and complex residue distribution through multi-physical field fusion technology (laser, ultrasound, temperature, pressure) and adaptive control algorithms, providing high-precision and high-consistency cleaning guarantee for solid content detection, and promoting the technological progress of the industry. Brief Description of the Drawings

[0027] The structures, ratios, sizes, etc. shown in this specification are only used to cooperate with the content disclosed in the specification for those familiar with this technology to understand and read, and are not used to limit the implementation conditions of the present invention. Therefore, they do not have technical essential significance.

[0028] Figure 1 It is a schematic structural diagram of the present invention.

[0029] Legend Explanation:

[0030] 1. Motor M1; 2. Flexible and telescopic electrostatic adsorption film; 3. Array laser head (blue light); 4. Low-frequency ultrasonic excitation body; 5. Milling cutter; 6. Optical fiber channel; 7. Horizontal fixed support; 8. Eccentric motor 2; 9. Detection kettle body; 10. Top platform; 12. Vertical cleaning track; 13. Adjusting cylinder 1; 14. Vertical adjusting track. Detailed Embodiments

[0031] Embodiment 1

[0032] As Figure 1 shown, an automatic cleaning device for a solid content detection kettle body includes:

[0033] Distributed ultrasonic sensing network. The sensing network is composed of arrayed piezoelectric ceramic chips (PZT) attached to the outer wall of the detection kettle body 9, and the vibration mode of the cylinder is excited by 50 kHz low-frequency ultrasonic waves to detect the frequency shift caused by the residues on the inner wall.

[0034] Laser scanning probe. The probe integrates a sapphire optical window and a compressed air curtain, and is installed 20 - 50 mm away from the inner wall of the detection kettle body 9. The thickness of the residues is measured through the peak value of the reflected light, with an accuracy of ±1u m , and the temperature drift is dynamically compensated.

[0035] The electrostatic adsorption mechanism includes a flexible and telescopic electrostatic adsorption film 2 and a motor M1. The outer diameter of the flexible and telescopic electrostatic adsorption film 2 is slightly smaller than the inner diameter of the detection kettle body 9, forming a gap of 1 - 1.5 mm with the inner wall. A voltage of 500 - 800 V is applied to adsorb dust. The surface of the flexible and telescopic electrostatic adsorption film 2 is covered with a polytetrafluoroethylene insulating layer and is connected to the grounding terminal of the detection kettle body 9 to prevent arc discharge;

[0036] The rotary milling cutter mechanism includes a milling cutter 5, an eccentric motor 2 and a horizontal fixed support 7. The diameter of the milling cutter 5 is 1 / 3 - 2 / 3 of the inner diameter of the detection kettle body 9, and it moves up and down through a vertical adjustment track 14 and an adjustment cylinder 1 for cutting large sintered residues;

[0037] The multi - physical - field fusion system fuses laser and ultrasonic data, calculates the thickness of the residue through a weighted average model, with the weight of laser data being 0.5u m , and the weight of ultrasonic data being 3u m , and corrects the measurement error based on the temperature drift compensation formula (Δd = a s ·ΔT·d raw +β e ·ΔT), where the thermal expansion coefficient a of sapphire s = 1.2×10 -5 ℃ -1 , and the electron drift coefficient β e = 3×10 -9 ℃ -1 , and the uncertainty after compensation ≤ 0.8u m .

[0038] The laser scanning probe is an 8 - probe annular array, with one probe distributed every 45°, and is axially scanned by a robotic arm.

[0039] The flexible and telescopic electrostatic adsorption film 2 of the electrostatic adsorption mechanism realizes circumferential rotation through the adjustment cylinder 1 on the top platform 10, and contracts to the standby position of the vertical cleaning track 12 after cleaning.

[0040] The milling cutter 5 is driven by the eccentric motor 2 to rotate at a speed of 100 - 300 rpm. There are air holes on the top of the milling cutter 5 to support local purging with high - pressure gas of 0.5 - 1.0 MPa.

[0041] The spatio - temporal registration algorithm of the multi - physical - field fusion system includes constructing a unified coordinate system (Z - axis, θ - angle, radial R), mapping the laser polar - angle data to the ultrasonic grid through polar coordinate transformation, aligning the data points using the bilinear interpolation method, and constraining the registration error ≤ ±0.5 mm.

[0042] A cleaning evaluation method for an automatic cleaning device of a solid - phase content detection kettle body includes the above - mentioned automatic cleaning device of the solid - phase content detection kettle body, and specifically includes the following steps:

[0043] Step 1: Initial cleaning stage, cutting large sintered residues with a rotary milling cutter 5;

[0044] Step 2: Multi-sensor detection stage, fusing laser and ultrasonic data to calculate the thickness of the residues;

[0045] Step 3: Fine cleaning stage, starting the electrostatic adsorption mechanism to remove dust according to the detection results;

[0046] Step 4: Cycle verification stage, the calculation formula of the cleanliness index (CDI): where D threshold = 20u m is the residue threshold. If the residue thickness exceeds 20u m , then repeat the fine cleaning and conduct high-pressure gas purging through the top air holes of the milling cutter (5). The gas pressure is 0.5 - 1.0 MPa, and the purging path is corrected in real time by the D final distribution. The purging time ≤ 30 seconds until CDI ≥ 95%, and the residue thickness meets the standard.

[0047] The airflow direction of the high-pressure gas purging is accurately aligned with the residue distribution area, and the purging path is corrected in real time by the detection data.

[0048] Example 2

[0049] Based on Example 1, in this example: Install the detection kettle body 9 on the vertical cleaning track 12 to ensure that the milling cutter 5 is aligned with the vertical adjustment track 14 through the horizontal fixed support 7. The flexible and telescopic electrostatic adsorption film 2 is adjusted to the initial contracted state by the motor M1 on the top platform 10. The piezoelectric ceramic chips (PZT) of the distributed ultrasonic sensing network are attached to the outer wall of the kettle body in a 10 cm × 10 cm array, and the laser probes 3 are annularly distributed at 45° intervals. The optical fiber channel 6 is connected to the data processing terminal.

[0050] Start the adjustment cylinder 1 to drive the milling cutter 5 to enter the detection kettle body 9 along the vertical adjustment track 14. The eccentric motor 2 drives the milling cutter to rotate at a speed of 200 rpm, and the cutting path covers the entire axial range of the kettle body (Z = 0 - 2 m) for 10 minutes to remove large drilling fluid sintered residues. After cutting, the adjustment cylinder 1 controls the milling cutter to withdraw from the kettle body.

[0051] Activate the ultrasonic sensing network, emit SH waves modulated by a 50 kHz Hanning window, and extract the characteristic frequency offset Δf from the received signal through FFT analysis to invert the residue thickness D ultrasonic ; The array laser head (blue light) 3 starts the compressed air curtain (flow rate 5 m / s) to scan the peak value of the reflected light on the inner wall and measure the residue thickness D laster (accuracy ±1u m), and compensate for temperature drift in real time (when T = 275 °C, Δd = +0.7u m ). The multi-physical field fusion system aligns laser data (polar coordinates) and ultrasonic data (gridded) to a unified coordinate system (Z-axis, θ angle, radial R), and calculates the fusion thickness through a weighted average model:

[0052]

[0053] After outputting the thickness distribution map, mark the exceeding-standard area (e.g., at θ = 45°, Z = 1.2 m, D final = 19.1u m , uncertainty U = 0.8u m ).

[0054] Adjust the cylinder 1 to drive the flexible and telescopic electrostatic adsorption film 2 to extend into the exceeding-standard area. A 1.2 mm gap is formed between the flexible and telescopic electrostatic adsorption film 2 and the inner wall of the detection kettle body 9. Apply an 800 V voltage to adsorb dust. After 5 minutes, the flexible and telescopic electrostatic adsorption film 2 shrinks to the top platform 10 and moves to the standby position. The secondary detection shows that the residual thickness at θ = 45°, Z = 1.2 m drops to 15.3u m , but there are still local punctate residues (D final = 18.5u m ). Immediately start high-pressure gas purging. The top air hole of the milling cutter 5 is connected to an external air source and purged at a pressure of 0.8 MPa for 20 seconds. The air flow path is corrected in real time according to the detection data. The final detection shows that the residual thickness ≤ 12u m (CDI ≥ 95%), and it is determined that the cleaning is qualified.

[0055] The working principle of the present invention:

[0056] Complementary to the large-range and rapid scanning by ultrasonic detection and the local high-precision data of the laser, combined with a weighted model to reduce the error of a single sensor; the sapphire window (a s = 1.2×10 -5 / °C) of the laser probe and the electronic drift coefficient (β e = 3×10 -9 / °C) compensation model eliminate the influence of the high-temperature environment; the detection data is fed back to the intelligent control unit in real time, and the rotational speed of the milling cutter, the adsorption voltage and the purging pressure are dynamically adjusted to achieve closed-loop adaptive cleaning. The traditional manual cleaning takes 120 minutes, while the present invention only takes 40 minutes, and the efficiency is increased by 66.7%; the comprehensive residue removal rate ≥ 99.5%, and the detection accuracy of the fusion thickness reaches ±0.8u m , which is 275% higher than that of single ultrasonic detection (error ≥ 3u m ).

[0057] The foregoing has shown and described the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments, and what is described in the above embodiments and the specification is only to illustrate the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements fall within the scope of the present invention as claimed.

Claims

1. An automatic cleaning device for a solid content detection kettle body, characterized in that, Comprising: A distributed ultrasonic sensing network, where the sensing network consists of array-type piezoelectric ceramic chips (PZT) attached to the outer wall of the detection kettle body (9), exciting the vibration mode of the cylinder through 50 kHz low-frequency ultrasonic waves, and detecting the frequency shift caused by the residues on the inner wall. Laser scanning probe, the probe integrates a sapphire optical window and a compressed air curtain, and is installed 20-50 mm away from the inner wall of the detection kettle body (9). The thickness of the residue is measured by the peak value of the reflected light, and the accuracy is ±1u m , and dynamically compensates for temperature drift; An electrostatic adsorption mechanism, including a flexible and telescopic electrostatic adsorption film (2) and a motor M1 (1). The outer diameter of the flexible and telescopic electrostatic adsorption film (2) is slightly smaller than the inner diameter of the detection kettle body (9), forming a 1 - 1.5 mm gap with the inner wall, applying a voltage of 500 - 800 V to adsorb dust. The surface of the flexible and telescopic electrostatic adsorption film (2) is covered with a polytetrafluoroethylene insulating layer and is connected to the grounding terminal of the detection kettle body (9) to prevent arc discharge. A rotary milling cutter mechanism, including a milling cutter (5), an eccentric motor 2 (8), and a horizontal fixed support (7). The diameter of the milling cutter (5) is 1 / 3 - 2 / 3 of the inner diameter of the detection kettle body (9), and its up and down movement is controlled by a vertical adjustment track (14) and an adjustment cylinder (1), and is used for cutting large sintered residues. Multi-physical field fusion system, which fuses laser and ultrasonic data, calculates the residue thickness through a weighted average model, and the weight of the laser data is 0.5u m , and the weight of the ultrasonic data is 3u m , and corrects the measurement error based on the temperature drift compensation formula (Δd = a s ·ΔT·d raw + β e ·ΔT), where d raw is the original laser measurement thickness, ΔT is the temperature change, and the thermal expansion coefficient a s of sapphire = 1.2×10 -5 °C -1 , and the electron drift coefficient β e = 3×10 -9 °C -1 , and the uncertainty after compensation ≤ 0.8u m .

2. The automatic cleaning device for the solid content detection kettle body according to claim 1, wherein: The laser scanning probe is an 8-probe annular array, with one probe distributed every 45°, and is axially scanned by a robotic arm.

3. The automatic cleaning device for the solid content detection kettle body according to claim 1, characterized in that: The flexible and telescopic electrostatic adsorption film (2) of the electrostatic adsorption mechanism realizes circumferential rotation through the adjustment cylinder 1 (13) on the top platform (10), and retracts to the standby position of the vertical cleaning track (12) after the cleaning is completed.

4. The automatic cleaning device for the solid content detection kettle body according to claim 1, characterized in that: The milling cutter (5) is driven by the eccentric motor 2 (8) to rotate at a speed of 100 - 300 rpm. There are air holes on the top of the milling cutter (5) to support local purging of high-pressure gas at 0.5 - 1.0 MPa.

5. An automatic cleaning device for a solid content detection kettle body according to claim 1, characterized in that: The spatio-temporal registration algorithm of the multi-physical field fusion system includes constructing a unified coordinate system (Z-axis, θ angle, radial R), linearly interpolating and aligning the laser polar coordinate data with the ultrasonic grid data, and constraining the registration error ≤ ±0.5 mm.

6. A cleaning evaluation method for an automatic cleaning device of a solid content detection kettle body, characterized in that, Including the automatic cleaning device for the solid-phase content detection kettle body described in any one of claims 1 - 5, specifically including the following steps: Step 1: Initial cleaning stage, cutting large sintered residues by the rotary milling cutter (5). Step 2: Multi-sensor detection stage, fusing laser and ultrasonic data to calculate the thickness of the residues. Step 3: Fine cleaning stage, starting the electrostatic adsorption mechanism to remove dust according to the detection results. Step 4: Loop verification stage, cleanliness index (CDI) calculation formula: where D threshold = 20u m is the residue threshold. If the residue thickness exceeds 20u m , repeat the fine cleaning and conduct high-pressure gas purging through the top air holes of the milling cutter (5). The gas pressure is 0.5 - 1.0 MPa, and the purging path is corrected in real time according to the D final distribution. The purging time ≤ 30 seconds until CDI ≥ 95% and the residue thickness meets the standard.

7. The cleaning evaluation method of an automatic cleaning device for a solid content detection kettle body according to claim 6, characterized in that: The air flow direction of the high-pressure gas purging is precisely aligned with the residue distribution area, and the purging path is corrected in real time by the detection data.

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