Cement scale removing system based on resonance effect

Abstract

A cement scale removing system based on the resonance effect comprises a composite vibration generating device, a vibration feedback control system and an adjustable fixing device, the composite vibration generating device is composed of a pneumatic vibration device and an ultrasonic vibration device, and the pneumatic vibration device and the ultrasonic vibration device are alternately installed on the adjustable fixing device; the device has the following beneficial effects that broadband vibration is generated through the composite vibration device, namely in a pneumatic-ultrasonic composite vibration mode, when the vibration frequency is matched with the inherent frequency of a scaling layer, the resonance effect is generated, the energy transmission efficiency is greatly improved, internal cracks of scaling are expanded, efficient descaling is achieved, the device can adapt to structures of different thicknesses, and the device is suitable for large-scale popularization and application. The long-standing problem of contradiction between descaling efficiency and energy consumption in the prior art is solved.

Description

Technical Field

[0001] This invention belongs to the field of mechanical cleaning technology, specifically relating to an automatic descaling system that uses the principle of vibration resonance to remove cement scale from the inner walls of cement tank trucks and storage containers. Background Technology

[0002] After prolonged use, cement transportation and storage equipment develops a hardened scale layer on its inner walls. Traditional manual removal methods are inefficient, labor-intensive, and prone to damaging the equipment. Existing mechanical descaling technologies suffer from drawbacks such as high energy consumption, poor adaptability, and inability to monitor in real time. For example, the currently used pneumatic impact descaling device fails to address frequency compatibility issues; the currently used rotary scraper descaling method suffers from numerous dead zones and rapid scraper wear. Therefore, this invention provides an automatic descaling system and method for removing cement scale from the inner walls of cement tank trucks and storage containers using the principle of vibration resonance, which is essential. Summary of the Invention

[0003] This invention addresses the shortcomings of existing technologies by providing a cement scale removal system based on the resonance effect, which solves the problems of low scale removal efficiency, high energy consumption, inability to adaptively adjust, and lack of equipment status monitoring in existing technologies.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A cement scale removal system based on resonance effect includes a composite vibration generator, a vibration feedback control system, and an adjustable fixing device. The composite vibration generator consists of a pneumatic vibration device and an ultrasonic vibration device, which are alternately installed on the adjustable fixing device.

[0006] The pneumatic vibration device includes a cylinder piston mechanism controlled by three solenoid valves. The cylinder piston mechanism includes a cylinder, a piston, a spring, a pipe, and three solenoid valves. A spring is provided between the inner top surface of the cylinder and the top surface of the piston. The pipe connects the upper chamber and the lower chamber of the cylinder, and the connection points are respectively close to the top of the upper chamber and the bottom of the lower chamber. A third solenoid valve is provided on the pipe connecting to the lower chamber. Air holes for air pipe connection are provided on the side walls of the cylinder near the top of the upper chamber and the bottom of the lower chamber. A first solenoid valve and a second solenoid valve are provided at the air pipe. The air pipe of the first solenoid valve is connected to air, and the air pipe of the second solenoid valve is connected to a high-pressure air source.

[0007] The vibration feedback control system includes a vibration sensor, a pressure sensor, and an electronic control unit. The electronic control unit receives monitoring signals from the vibration sensor and the pressure sensor, and performs judgment and processing according to preset logic. It then sends commands to solenoid valve one, solenoid valve two, solenoid valve three, and the ultrasonic transducer of the ultrasonic vibration device to control their opening and closing.

[0008] Furthermore, the adjustable fixing device adopts a prestressed steel strip structure and is equipped with preload adjustment bolts.

[0009] Furthermore, the vibration sensor is mounted on the surface of the descaling equipment.

[0010] Furthermore, the air pressure sensor is installed on the air pipe at the front end of the second solenoid valve.

[0011] Beneficial effects

[0012] Compared with the prior art, the present invention has the following beneficial effects: By using a composite vibration device, namely a pneumatic-ultrasonic composite vibration method to generate broadband vibration, a resonance effect is generated when the vibration frequency matches the natural frequency of the scale layer, which greatly improves the energy transfer efficiency, causes the internal cracks of the scale to expand, achieves efficient scale removal, can adapt to structures of different thicknesses, and solves the problem of the contradiction between scale removal efficiency and energy consumption that has long existed in the prior art. Attached Figure Description

[0013] Figure 1 This is a schematic diagram illustrating the usage state of the present invention;

[0014] Figure 2 This is a schematic diagram of the piston's upward spring energy storage state according to the present invention;

[0015] Figure 3 This is a schematic diagram of the piston impacting the base plate during its downward movement, as per the present invention.

[0016] Figure 4 This is a cross-sectional view of the connection between the pneumatic vibration device and the adjustable fixing device of the present invention.

[0017] Figure 5 This is a top view of the pneumatic vibration device and the adjustable fixing device of the present invention in a connected state.

[0018] Figure 6 This is a cross-sectional view of the connection between the ultrasonic vibration device and the adjustable fixing device of the present invention.

[0019] Figure 7 This is a top view of the ultrasonic vibration device and the adjustable fixing device of the present invention in a connected state.

[0020] Figure 8 This is a schematic diagram illustrating the working principle of the present invention.

[0021] Explanation of reference numerals in the attached drawings: 1. Composite vibration generator; 11. Pneumatic vibration device; 111. Cylinder; 112. Piston; 113. Spring; 114. Pipeline; 115. Solenoid valve one; 116. Solenoid valve two; 117. Solenoid valve three; 118. Base plate; 119. Limiting rod; 12. Ultrasonic vibration device; 2. Vibration feedback control system; 21. Vibration sensor; 22. Air pressure sensor; 221. Air pressure alarm device; 23. Electronic control unit; 3. Adjustable fixing device; 31. Preload adjusting bolt. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Those skilled in the art should connect all electrical components and their compatible power supplies in this case via wires. Appropriate controllers and encoders should be selected according to the actual situation to meet control requirements. The specific connection and control sequence should refer to the working principle described below, where the electrical components are connected in sequence. The detailed connection methods are well-known in the art. The following mainly introduces the working principle and process, and will not describe the electrical control further.

[0024] Please see Figures 1-8 A cement scale removal system based on resonance effect includes a composite vibration generator 1, a vibration feedback control system 2, and an adjustable fixing device 3. The composite vibration generator 1 consists of a pneumatic vibration device 11 and an ultrasonic vibration device 12, which are alternately installed on the adjustable fixing device 3.

[0025] The pneumatic vibration device 11 includes a cylinder piston mechanism controlled by three solenoid valves. The cylinder piston mechanism includes a cylinder 111, a piston 112, a spring 113, a pipe 114, and three solenoid valves. A spring 113 is provided between the inner top surface of the cylinder 111 and the top surface of the piston 112. The pipe 114 connects the upper chamber and the lower chamber of the cylinder 111, and the connection points are respectively close to the top of the upper chamber and the bottom of the lower chamber. A solenoid valve 117 is provided on the pipe connecting to the lower chamber. Air holes for air pipe connection are provided on the side walls of the cylinder 111 near the top of the upper chamber and the bottom of the lower chamber. A solenoid valve 115 and a solenoid valve 116 are provided at the air pipe. The air pipe at solenoid valve 115 is connected to air, and the air pipe at solenoid valve 116 is connected to a high-pressure air source.

[0026] The vibration feedback control system 2 includes a vibration sensor 21, a pressure sensor 22, and an electronic control unit 23. The electronic control unit 23 receives the monitoring signals from the vibration sensor 21 and the pressure sensor 22, and performs judgment and processing according to preset logic. It sends commands to solenoid valve one, solenoid valve two, solenoid valve three, and the ultrasonic transducer of the ultrasonic vibration device to control their opening and closing.

[0027] As a preferred option, the adjustable fixing device 3 adopts a prestressed steel strip structure and is equipped with a preload adjustment bolt 31.

[0028] As a preferred option, the vibration sensor 21 is further mounted on the surface of the descaling equipment.

[0029] As a preferred option, the air pressure sensor 22 is further installed on the air pipe at the front end of the solenoid valve 2 116 to monitor the air pressure at the air source. If the air pressure at the air source does not reach the preset value, the control unit controls the air pressure alarm device to sound an alarm, prompting the operator to replace the air source.

[0030] Working principle:

[0031] When performing descaling operations, a pneumatic vibration device 11 is used at low frequencies. The working frequency of the pneumatic vibration device 11 can be initially set at 50Hz, but is not limited to this. For high frequencies, an ultrasonic vibration device 12 is used. The working frequency of the ultrasonic vibration device can be initially set at 20kHz, but is not limited to this. The core principle of using vibration to remove cement scale in cement tank trucks and cement storage containers is based on the energy transfer of vibration and the fatigue effect of materials. Mechanical vibration at a specific frequency and amplitude breaks the bonding force between the scale and the matrix. When the vibration frequency is close to the natural frequency of the cement scale or the matrix, resonance will be triggered, which will greatly improve the energy transfer efficiency and cause the internal cracks of the scale to expand. The typical frequency range of cement scale is: low frequency (50-500Hz) is more effective for brittle cement, and high frequency (20kHz-40kHz) is suitable for penetration through micropores.

[0032] When performing descaling operations,

[0033] 1. Prioritize the "processing scenario": If dealing with cement scale of a certain depth or large area in pipes, containers, etc., pneumatic vibration device should be selected first, as low frequency can achieve a larger range of action; if dealing with shallow surfaces such as equipment surfaces and small parts that require fine descaling, ultrasonic vibration device can be selected, as high frequency descaling efficiency is higher.

[0034] 2. Next, consider the "scale condition": For thick, hard, aged cement scale, it is recommended to first use a pneumatic vibration device to "break up" the outer hard scale at low frequency, and then use an ultrasonic vibration device to clean the remaining thin layer at high frequency; for thin, brittle, newly formed cement scale, an ultrasonic vibration device can be used directly, which can balance efficiency and range.

[0035] 3. Finally, confirm “Equipment Compatibility”: The ultrasonic vibration device 12 must be matched with the rated frequency of the ultrasonic generator and transducer (such as industrial equipment that often supports 20kHz / 28kHz / 40kHz standard settings) to avoid power loss or equipment damage due to frequency mismatch.

[0036] Workflow:

[0037] First, install: (e.g.) Figure 1 As shown, pneumatic vibration devices 11 and ultrasonic vibration devices 12 are alternately installed on the adjustable fixing device 3. The adjustable fixing device 3 is mainly based on a steel belt, on which several pneumatic vibration devices 11 and ultrasonic vibration devices 12 are alternately distributed around the circumference. The connecting end of the steel belt is connected by a pre-tightening adjustment bolt 31.

[0038] Both the pneumatic vibration device 11 and the ultrasonic vibration device 12 can be fixed to the steel belt by bolts, such as Figure 4 , Figure 5 As shown, the pneumatic vibration device can be fixed to the steel strip using two countersunk screws from the inside out, as shown. Figure 6 .、 Figure 7 As shown, the ultrasonic vibration device can be fixed by a countersunk screw from the inside out. After installation, the adjustable fixing device 3 is installed on the surface of the cement tank or the cement storage container and fixed by the pre-tightening bolt 31. Adjust the pre-tightening force so that the steel belt fits the tank completely and the vibration effect is transmitted to the descaling equipment in the best way.

[0039] The system then starts up, first pre-processing in pneumatic vibration mode, and then switching to ultrasonic vibration mode. The switching between pneumatic and ultrasonic vibration modes is based on the monitoring data from the vibration sensor.

[0040] Pneumatic vibration devices, such as Figure 2 , Figure 3 As shown, piston 112 is installed inside cylinder 111. Piston 112 can reciprocate up and down inside the cylinder. Solenoid valve 115, solenoid valve 216, and solenoid valve 317 are all normally closed solenoid valves. The pipeline of solenoid valve 2 is connected to a high-pressure air source (the air source can be the compressed gas provided by the car or an independent compressed air device, such as an air pump). Solenoid valve 3 controls the connection between the upper and lower chambers of the cylinder. Solenoid valve 1 controls the connection between the upper chamber of the cylinder and the atmosphere. Spring 113 is installed on the upper part of the piston and is located in the upper chamber of the cylinder.

[0041] During operation, the piston moves up and down, impacting the bottom plate 118 downwards (if it is a newly manufactured tank, the pneumatic vibration device and ultrasonic vibration device can be directly fabricated on the tank; if it is an old device, they are added to the original tank via a steel belt), generating strong vibrations.

[0042] Piston upward movement: Electronic control unit 23 first opens solenoid valve 115 and solenoid valve 216, such as Figure 2 As shown, at this time, high-pressure gas enters the lower chamber of the cylinder from the pipeline at the second solenoid valve. Under the action of the high-pressure gas, the piston 112 overcomes the spring force and moves upward. At this time, the spring is compressed and stores energy.

[0043] Piston moves downward: Electronic control unit 23 controls solenoid valve 3 to open, such as Figure 3 As shown, when solenoid valve 3 is opened, the high-pressure gas in the cylinder is discharged to the upper end of the piston. At this time, the high-pressure gas and the spring work together to push the piston down and violently hit the bottom plate to achieve the vibration function.

[0044] Throughout the process, the electronic control unit 23 switches the solenoid valve 3 on and off according to the required frequency, controlling the piston to move up or down, thereby achieving vibration at different frequencies.

[0045] This invention can also be used for descaling static storage tanks, and can adopt a multi-frequency alternating working mode, for example, it can use pneumatic 120Hz / ultrasonic 80kHz circulation to achieve the function of descaling static storage tanks.

[0046] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A cement scale removal system based on resonance effect, comprising a composite vibration generator (1), a vibration feedback control system (2), and an adjustable fixing device (3), characterized in that: The composite vibration generating device (1) consists of a pneumatic vibration device (11) and an ultrasonic vibration device (12), which are alternately installed on the adjustable fixing device (3). The pneumatic vibration device (11) includes a cylinder piston mechanism controlled by three solenoid valves. The cylinder piston mechanism includes a cylinder (111), a piston (112), a spring (113), a pipe (114), and three solenoid valves. A spring (113) is provided between the inner top surface of the cylinder (111) and the top surface of the piston (112). The pipe (114) connects the upper chamber and the lower chamber of the cylinder (111), and the connection is close to the top of the upper chamber and the bottom of the lower chamber, respectively. A solenoid valve three (117) is provided on the pipe connecting the lower chamber. Air holes for air pipe connection are provided on the side walls of the cylinder (111) near the top of the upper chamber and the bottom of the lower chamber. A solenoid valve one (115) and a solenoid valve two (116) are provided at the air pipe. The air pipe at the solenoid valve one (115) is connected to air, and the air pipe at the solenoid valve two (116) is connected to a high-pressure air source. The vibration feedback control system (2) includes a vibration sensor (21), a pressure sensor (22), and an electronic control unit (23). The electronic control unit (23) receives the monitoring signals from the vibration sensor (21) and the pressure sensor (22), and makes judgments and processes them according to preset logic. It sends commands to the solenoid valve one, solenoid valve two, solenoid valve three, and the ultrasonic transducer of the ultrasonic vibration device to control them to open and close.

2. The cement scale removal system based on resonance effect according to claim 1, characterized in that: The adjustable fixing device (3) adopts a prestressed steel strip structure and is equipped with a pre-tightening force adjusting bolt (31).

3. The cement scale removal system based on resonance effect according to claim 1, characterized in that: The vibration sensor (21) is installed on the surface of the descaling equipment.

4. The cement scale removal system based on resonance effect according to claim 1, characterized in that: The air pressure sensor (22) is installed on the air pipe at the front end of the solenoid valve (116).

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