Equipment transformation method based on capacity expansion of buffer tank system of mixer

Abstract

The invention discloses an equipment transformation method based on capacity expansion of a mixer buffer tank system. The capacity of the mixer system is improved through a composite buffer tank capacity expansion module. The method comprises the following steps: (1) analyzing airflow resistance by using a multi-channel pressure acquisition device, and determining a capacity expansion bottleneck; (2) a composite module is configured and comprises a main buffer tank body (with a built-in spiral guide plate) and a parallel micro booster tank (connected through a controllable diverter valve and a flexible connecting pipe), and an airflow pretreatment unit is additionally arranged; (3) a module is installed, a dynamic expansion loop is formed through a flow divider valve and an external controller, and a booster pump is activated during high load; and (4) optimizing the airflow stability by using a built-in flow equalizer and a temperature compensation device. By precisely positioning the bottleneck and dynamically adjusting the capacity, the gas supply efficiency and stability are remarkably improved, the modification cost is reduced, the service life of equipment is prolonged, and the device is suitable for various mixer stations and has popularization value.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial gas supply equipment and relates to a method for equipment transformation based on the capacity expansion of a mixer buffer tank system. Background Art

[0002] The mixer buffer tank system is a core component in industrial gas supply and is widely used in industries such as automobile manufacturing, medical oxygen supply, and machining for storing and regulating mixed gases or single gases to meet production or usage requirements. With the continuous expansion of industrial production scale and the continuous growth of gas consumption demand, many existing mixer stations are facing the problem of insufficient buffer tank capacity. As an important gas storage unit in the mixer system, the performance of the buffer tank directly affects the gas supply efficiency and stability. However, after long-term operation, the buffer tank often fails to adapt to the high-load requirements of modern production due to aging, internal structure wear, or design capacity limitations. For example, in the field of automobile manufacturing, the mixer station needs to provide stable mixed gas for welding or cutting processes, and old buffer tanks may cause gas supply interruption or pressure fluctuations due to increased air flow resistance or insufficient capacity, directly affecting the continuity of the production line and product quality.

[0003] Traditionally, there are various methods for capacity expansion transformation of the mixer buffer tank system, but all of them have significant limitations. A common solution is to replace the entire mixer equipment, including the buffer tank, valves, and control system. However, this method is extremely costly, and the replacement cost of a mixer equipment is often as high as hundreds of thousands of yuan, and the replacement process requires production suspension for construction, seriously affecting the normal operation of the enterprise. Another method is to directly replace the buffer tank of the same model. Although this method has relatively low cost, it can only restore the original capacity and cannot achieve system capacity expansion. Moreover, the installation of the new tank may lead to uneven air flow distribution or unstable system operation due to insufficient matching with the existing mixer. In addition, there are also technologies to deal with performance degradation by extending the service life of the buffer tank (such as internal repair or coating renovation), but this method is only applicable to mild aging conditions and is powerless for capacity bottleneck problems.

[0004] The prior art also faces other challenges in capacity expansion transformation. For example, the operating environments of many mixer stations are complex, such as terrain restrictions, narrow spaces, or high-temperature and high-humidity conditions, making it extremely difficult to implement traditional transformation methods. During the construction process, the deployment and lifting transportation of mechanical equipment are restricted, resulting in an extended transformation period and increased safety risks. At the same time, the existing methods lack accurate analysis of system capacity expansion requirements. Usually, the buffer tank status is judged only by experience or years, and the air flow resistance distribution or pressure bottleneck cannot be effectively identified, resulting in insufficient pertinence of the transformation plan. In addition, it is difficult to ensure the stability of the air flow output of the system after traditional transformation. Especially during high-load operation, gas supply fluctuations may cause failures or efficiency decline of production equipment.

[0005] In recent years, with the increasingly urgent demand for efficient and low-cost solutions in the industrial gas industry, some new technologies have been tried and applied to the transformation of the mixer system. For example, the gas supply capacity is increased by adding additional mixer equipment. However, this method not only has high costs but also occupies a large area, making it unsuitable for sites with limited space. Some other studies have explored capacity expansion by adjusting gas supply parameters (such as pressure or flow rate), but this method is highly dependent on existing equipment. If the capacity of the buffer tank itself is insufficient, the effect will be limited. In contrast, there are fewer solutions for directly structurally transforming the buffer tank system, and existing solutions mostly remain at the level of simple replacement or partial optimization, lacking systematic innovation. In particular, for how to achieve capacity improvement through the composite design and dynamic adjustment of the buffer tank without replacing the main body of the mixer, no mature solution has been proposed in the existing technology.

[0006] In summary, the existing methods for expanding the capacity of the mixer buffer tank system have deficiencies in cost control, capacity expansion efficiency, and operation stability, and it is difficult to meet the high standards of modern industry for gas supply systems. Therefore, there is an urgent need for an innovative transformation method that can accurately locate the capacity expansion bottleneck at a relatively low cost, achieve system capacity improvement through structural optimization and dynamic adjustment, and ensure the stability and reliability of gas supply after the transformation. The present invention is proposed under this background, aiming to provide a new solution for the capacity expansion transformation of the mixer system through a composite buffer tank capacity expansion module and related technical means. Summary of the Invention

[0007] In view of this, the purpose of the present invention is to solve the above problems, and provide an equipment transformation method for expanding the capacity of the mixer buffer tank system, which realizes the capacity improvement of the mixer system through a composite buffer tank capacity expansion module, and solves the problems of low capacity expansion efficiency, high cost, and insufficient stability in the existing technology.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] An equipment transformation method for expanding the capacity of the mixer buffer tank system, which realizes the capacity improvement of the mixer system through a composite buffer tank capacity expansion module, includes the following steps:

[0010] (1) Conduct an analysis of the capacity expansion requirements for the buffer tank system of the existing mixer site, measure the dynamic air flow resistance between the buffer tank and the mixer through a multi-channel pressure acquisition device, and determine the capacity expansion bottleneck;

[0011] (2) Design and configure a composite buffer tank capacity expansion module. The composite buffer tank capacity expansion module includes a main buffer tank body and a parallel micro-booster tank. The micro-booster tank is connected to the main buffer tank body through a controllable flow divider valve;

[0012] (3) Install the composite buffer tank capacity expansion module at the mixer site, and adjust the air flow distribution between the main buffer tank body and the micro-booster tank through a shunt valve to form a dynamic capacity expansion loop;

[0013] (4) Adjust the parameter matching of the modified buffer tank system and the mixer, and optimize the air flow output stability by using the built-in flow equalizer.

[0014] Further, the multi-channel pressure acquisition device in step (1) includes at least four pressure sensors distributed circumferentially along the buffer tank, which are used to monitor the air flow resistance distribution in real time, and the capacity expansion bottleneck is determined by analyzing the peak value of the air flow resistance.

[0015] Further, a spiral guide plate is provided in the main buffer tank body of the composite buffer tank capacity expansion module in step (2), and the spiral guide plate is used to enhance the uniform distribution of the air flow in the tank body.

[0016] Further, the micro-booster tank in step (2) has an independent air inlet and air outlet, and the controllable shunt valve adopts an electromagnetic drive structure to adjust the air flow ratio between the main buffer tank body and the micro-booster tank according to the load demand of the mixer.

[0017] Further, the micro-booster tank in step (2) is connected to the main buffer tank body through a flexible connecting pipe, and a pressure self-adaptive adjustment membrane is embedded in the flexible connecting pipe to relieve the pressure fluctuation caused by the air flow mutation.

[0018] Further, the dynamic capacity expansion loop in step (3) is formed by the parallel operation of the main buffer tank body and the micro-booster tank, and the micro-booster tank is activated by a booster pump under high load to provide additional air flow support.

[0019] Further, the controllable shunt valve in step (3) is connected to an external controller, and the external controller adjusts the opening degree of the shunt valve in real time according to the operation state of the mixer.

[0020] Further, the built-in flow equalizer in step (4) includes a multi-stage orifice plate structure, and the air flow output of the buffer tank system and the mixer is balanced by adjusting the orifice diameter distribution.

[0021] Further, step (4) also includes thermal balance adjustment of the buffer tank system through a temperature compensation device, and the temperature compensation device includes a heat conduction ring surrounding the main buffer tank body and a temperature control unit.

[0022] Further, the composite buffer tank capacity expansion module also includes an air flow pretreatment unit, which is arranged at the air inlet end of the main buffer tank body and is used to filter and pre-adjust the humidity and particulate matter content of the input gas.

[0023] The beneficial effects of the present invention are as follows:

[0024] 1. Precise positioning of capacity expansion requirements and enhanced pertinence of transformation: By using a multi-channel pressure acquisition device to monitor the dynamic airflow resistance between the buffer tank and the mixer in real time, it is possible to accurately identify the capacity expansion bottlenecks in the system, overcoming the limitations of traditional methods that rely on empirical judgment or simple age assessment. This data-driven analysis method ensures that the transformation plan is formulated for specific problems, avoiding resource waste caused by blind replacement or over-design.

[0025] 2. High-efficiency capacity expansion and reduced transformation costs: The composite buffer tank capacity expansion module, through the parallel design of the main buffer tank body and the micro-booster tank, combined with a dynamic expansion circuit, significantly increases the system capacity without replacing the main body of the mixer. Compared with the high cost of replacing the mixer equipment as a whole, the present invention only needs to transform the buffer tank part, greatly reducing the economic investment, shortening the construction period, and reducing the production stoppage losses.

[0026] 3. Dynamic adjustment to adapt to variable loads: The micro-booster tank realizes dynamic adjustment of airflow distribution through a controllable flow divider valve and a booster pump, and can flexibly switch the operating mode according to the load requirements of the mixer. It maintains the operation of the main buffer tank body at low loads and activates booster support at high loads. This self-adaptive ability enables the system to operate efficiently under different working conditions, significantly enhancing the gas supply flexibility.

[0027] 4. Optimize airflow stability and ensure operation reliability: The built-in flow equalizer balances the airflow output through a multi-stage orifice plate structure, the spiral guide plate enhances the airflow uniformity in the tank, the flexible connecting pipe alleviates the pressure fluctuation, and the temperature compensation device maintains the thermal balance. These technical means work together to ensure that the transformed system can still provide a stable gas supply under high loads or complex environments, avoiding problems such as gas supply fluctuations or equipment failures that may occur after traditional transformations.

[0028] 5. Improve environmental adaptability and extend equipment life: The airflow pretreatment unit filters the particulate matter of the input gas and adjusts the humidity, reducing the risk of corrosion and blockage inside the buffer tank and extending the service life of the equipment. At the same time, the design of the flexible connecting pipe and the pressure self-adaptive adjustment membrane reduces the impact of sudden airflow changes on the system, further improving the durability of the system.

[0029] 6. Wide applicability and high promotion value: This method is applicable to various mixer stations. Whether it is for industrial mixed gas supply or medical oxygen stations, capacity expansion transformation can be achieved by adjusting the module parameters. Its modular design is convenient for standardized production and rapid deployment, with significant potential for industry promotion.

[0030] Other advantages, objectives and features of the present invention will be described to some extent in the subsequent specification, and to some extent, will be obvious to those skilled in the art based on the study of the following text, or can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be achieved and obtained through the following specification. Detailed implementation mode

[0031] The following uses specific specific examples to illustrate the implementation mode of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific implementation modes. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0032] A method for equipment transformation based on the capacity expansion of a mixer buffer tank system, which realizes the capacity improvement of the mixer system through a composite buffer tank expansion module, includes the following steps:

[0033] (1) Conduct an analysis of the capacity expansion requirements for the buffer tank system of the existing mixer site, measure the dynamic airflow resistance between the buffer tank and the mixer through a multi-channel pressure acquisition device, and determine the capacity expansion bottleneck;

[0034] (2) Design and configure a composite buffer tank expansion module, which includes a main buffer tank body and a parallel micro-booster tank. The micro-booster tank is connected to the main buffer tank body through a controllable flow splitting valve;

[0035] (3) Install the composite buffer tank expansion module to the mixer site, adjust the airflow distribution between the main buffer tank body and the micro-booster tank through the flow splitting valve, and form a dynamic capacity expansion loop;

[0036] (4) Adjust the parameter matching between the transformed buffer tank system and the mixer, and optimize the stability of the airflow output by using the built-in flow equalizer.

[0037] Example 1

[0038] This example realizes the capacity improvement of the mixer system through a composite buffer tank expansion module.

[0039] In step (1), a multi-channel pressure acquisition device (at least four pressure sensors) is used to measure the airflow resistance and determine the capacity expansion bottleneck;

[0040] In step (2), configure a composite module, including a main buffer tank body (with a spiral guide plate inside) and a parallel micro-booster tank (connected through a flexible connecting pipe and an electromagnetic flow splitting valve), and install an airflow pretreatment unit;

[0041] Step (3) Install the module, form a dynamic expansion loop through the flow dividing valve and the external controller, and activate the booster pump under high load;

[0042] Step (4) Optimize the stability by using a multi-stage orifice flow equalizer and a temperature compensation device (heat conduction ring and temperature control unit).

[0043] Specific implementation: At a certain mixing station, the existing system capacity is insufficient. Step (1) Install 4 pressure sensors (model PT-100, 0 - 10 MPa), operate for 48 hours, measure the peak resistance at the gas outlet end as 2.5 MPa, and determine the bottleneck. Step (2) Select the main buffer tank body (model 296MX-200, volume 200 m 3 , the angle of the spiral guide plate is 45°), connect in parallel with a micro-booster tank (volume 50 L, independent air inlet and outlet), connect through a flexible connecting pipe (embedded with an adjustment membrane) and an electromagnetic flow dividing valve (SV-01), and install a pretreatment unit (filtration accuracy 5 μm, humidity 40%) at the air inlet end. After step (3) installation, the initial opening of the flow dividing valve is 50%, and the external controller (PLCS7-1200) is adjusted to 60% - 80%. When under high load, the booster pump is increased to 3 MPa. Step (4) Install a flow equalizer (three-stage orifice plates, 10 mm, 8 mm, 6 mm) and a temperature compensation device (copper heat conduction ring, temperature control at 25 °C). After the transformation, the gas supply capacity is significantly improved.

[0044] Example 2

[0045] The technical solution of this example is the same as above:

[0046] Step (1) Precisely locate the bottleneck through multi-channel pressure acquisition;

[0047] Step (2) Configure a composite module. The main buffer tank body contains a spiral guide plate. The micro-booster tank is connected through a flexible connecting pipe and a flow dividing valve, and includes a pretreatment unit;

[0048] Step (3) Form a dynamic expansion loop, the controller adjusts the flow dividing valve, and the booster pump supports high load;

[0049] Step (4) Optimize the air flow with a flow equalizer and a temperature compensation device.

[0050] Specific implementation: At the external medical oxygen station of a certain hospital, the main buffer tank body (model 296MX-100, volume 100 m 3, the angle of the spiral deflector is 45°), a micro-booster tank (volume 30L), connected by a flexible connecting pipe and a flow dividing valve (SV-01), and the pretreatment unit adjusts the humidity to 50%. In step (1), the peak resistance is measured to be 2.0 MPa. In step (3), the opening of the flow dividing valve is adjusted to 40%-70%, and the pressure of the booster pump is 2.5 MPa. In step (4), a flow equalizer (three-stage orifice plate, 8mm, 6mm, 4mm), a temperature compensation device (temperature control 22°C). After the transformation, the oxygen supply is stable.

[0051] Example 3

[0052] The technical solution of this embodiment also includes:

[0053] In step (1), a pressure acquisition device is used to analyze the bottleneck;

[0054] In step (2), the composite module includes a main buffer tank body (spiral deflector), a micro-booster tank (flexible connection, flow dividing valve) and a pretreatment unit;

[0055] In step (3), the dynamic expansion loop is supported by a controller and a booster pump;

[0056] In step (4), a flow equalizer and a temperature compensation device optimize the stability.

[0057] Specific implementation: At a mixer station in a certain factory, the main buffer tank body (model 296MX-200, volume 200m 3 ), a micro-booster tank (volume 50L, booster pump 5kW), a pretreatment unit (filtration accuracy 3μm). In step (1), the peak resistance is 2.8 MPa. In step (3), the opening of the flow dividing valve is 50%-85%, and the pressure of the booster pump is 3.5 MPa. In step (4), a flow equalizer (four-stage orifice plate, 12mm, 10mm, 8mm, 6mm), a temperature compensation device (temperature control 28°C). The system runs smoothly.

[0058] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the present technical solution, and they should all be covered by the scope of the claims of the present invention.

Claims

1. A method for equipment transformation based on the capacity expansion of a mixer buffer tank system, characterized in that, Capacity improvement of the mixer system is achieved through a composite buffer tank capacity expansion module, including the following steps: (1) Conduct an analysis of the capacity expansion requirements for the buffer tank system of the existing mixer site. Measure the dynamic airflow resistance between the buffer tank and the mixer through a multi-channel pressure acquisition device to determine the capacity expansion bottleneck; (2) Design and configure a composite buffer tank capacity expansion module. The composite buffer tank capacity expansion module includes a main buffer tank body and a parallel-type micro-booster tank. The micro-booster tank is connected to the main buffer tank body through a controllable flow-dividing valve; (3) Install the composite buffer tank capacity expansion module at the mixer site. Adjust the airflow distribution between the main buffer tank body and the micro-booster tank through the flow-dividing valve to form a dynamic capacity expansion loop; (4) Adjust the parameter matching between the modified buffer tank system and the mixer, and use the built-in flow equalizer to optimize the stability of the airflow output.

2. The equipment transformation method for capacity expansion based on the mixer buffer tank system according to claim 1, wherein The multi-channel pressure acquisition device in step (1) includes at least four pressure sensors circumferentially distributed along the buffer tank, which are used to monitor the airflow resistance distribution in real time. The capacity expansion bottleneck is determined by analyzing the airflow resistance peak value.

3. The equipment transformation method for capacity expansion based on the mixer buffer tank system according to claim 1, wherein The main buffer tank body of the composite buffer tank capacity expansion module in step (2) is provided with a spiral guide plate, which is used to enhance the uniform distribution of the airflow in the tank body.

4. The equipment transformation method for capacity expansion based on the mixer buffer tank system according to claim 1, wherein The micro-booster tank in step (2) has an independent air inlet and an exhaust port. The controllable flow-dividing valve adopts an electromagnetic drive structure to adjust the airflow ratio between the main buffer tank body and the micro-booster tank according to the load demand of the mixer.

5. The equipment transformation method for expanding the capacity of the mixer buffer tank system according to claim 1, characterized in that The micro-booster tank in step (2) is connected to the main buffer tank body through a flexible connecting pipe. The flexible connecting pipe is embedded with a pressure self-adaptive adjustment membrane, which is used to relieve the pressure fluctuation caused by the sudden change of the airflow.

6. The equipment transformation method for expanding the capacity based on the mixer buffer tank system according to claim 1, characterized in that The dynamic capacity expansion loop in step (3) is formed by the parallel operation of the main buffer tank body and the micro-booster tank. Among them, the micro-booster tank is activated by a booster pump under high load to provide additional airflow support.

7. The equipment transformation method for expanding the capacity of the mixer buffer tank system according to claim 1, characterized in that, The controllable flow-dividing valve in step (3) is connected to an external controller, and the external controller adjusts the opening degree of the flow-dividing valve in real time according to the operating state of the mixer.

8. The equipment transformation method for expanding the capacity of the mixer buffer tank system according to claim 1, wherein The built-in flow equalizer in step (4) includes a multi-stage orifice plate structure, and the airflow output of the buffer tank system and the mixer is balanced by adjusting the orifice diameter distribution of the orifice plate.

9. The equipment transformation method for capacity expansion based on the mixer buffer tank system according to claim 1, characterized in that Step (4) also includes thermal balance adjustment of the buffer tank system through a temperature compensation device. The temperature compensation device includes a heat conduction ring surrounding the main buffer tank body and a temperature control unit.

10. The equipment transformation method for expanding the capacity based on the mixer buffer tank system according to claim 1, wherein, The composite buffer tank capacity expansion module also includes an airflow pretreatment unit, which is arranged at the air inlet end of the main buffer tank body and is used to filter and pre-adjust the humidity and particulate matter content of the input gas.