A pipeline anti-blocking system with vibration damping positioning and ultrasonic vibration cavitation drag reduction

Abstract

The application relates to the technical field of pipeline anti-blocking, in particular to a pipeline anti-blocking system with vibration attenuation positioning and ultrasonic vibration cavitation drag reduction. In the anti-blocking system, a vibration sensor is used to collect vibration response signals of ultrasonic vibration propagation and attenuation in the pipeline in real time, which is conducive to improving the monitoring accuracy of the pipeline operation state. After the control module determines that the pipeline position corresponding to a certain set of anti-blocking systems is blocked, the control module sends an adjustment signal to the ultrasonic vibration assembly of the anti-blocking system corresponding to the blocked position of the pipeline, so as to improve the specific working parameters of the ultrasonic vibration assembly, make the ultrasonic vibration assembly produce greater ultrasonic vibration, produce cavitation effect under the action of the ultrasonic vibration, guide flow by the spiral blade, make the fluid concentration tend to be uniform along the cross-section direction, inhibit particle deposition, improve the local flow field state, realize the dredging of the pipeline, and reduce the possibility of pipeline blockage and improve the conveying stability, and the original pipeline structure does not need to be changed.

Description

Technical Field

[0001] This application relates to the field of pipeline anti-clogging technology, and in particular to a pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction. Background Technology

[0002] During tailings slurry transportation, as the solid content of the slurry increases, the length of the transportation pipeline extends, and the actual operating conditions fluctuate more, local sedimentation zones are easily formed inside the pipeline. These sedimentation zones generally occur in long straight sections, areas of local pressure drop reversal, or sections of flow velocity decay, and further lead to particle aggregation, localized increases in concentration, and continuous expansion of the sediment layer, thereby increasing the transportation resistance and ultimately causing blockage.

[0003] Current methods for preventing sediment buildup mainly include chemical dispersion, periodic backwashing, and built-in baffles, but all of these methods have significant limitations. Using chemical methods to inhibit sediment formation introduces additional operating costs and pollution problems, and is difficult to control in real time; using backwashing requires stopping the operation, which is detrimental to the continuity of transportation; and using built-in baffles requires the installation of cracked pipes, which weakens the structure.

[0004] Therefore, there is a need to provide an improved technical solution that addresses the shortcomings of the existing technology. Summary of the Invention

[0005] The purpose of this application is to provide a pipeline anti-clogging system that combines vibration attenuation positioning and ultrasonic vibration cavitation drag reduction, in order to solve or alleviate the problems existing in the prior art.

[0006] To achieve the above objectives, this application provides the following technical solution:

[0007] A pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction is provided, wherein an anti-clogging system is installed at each easily clogged location on the pipeline, and multiple anti-clogging systems are electrically connected to a control module.

[0008] The anti-blocking system includes:

[0009] Inner sleeve, the inner sleeve being installed inside the pipe;

[0010] Helical blades: Multiple helical blades are evenly distributed on the inner wall of the inner sleeve for guiding flow;

[0011] An ultrasonic vibration assembly is installed on the outer wall of the pipe, and the installation position of the ultrasonic vibration assembly corresponds to the installation position of the inner sleeve. The ultrasonic vibration assembly is used to generate ultrasonic vibration.

[0012] The monitoring unit includes at least one vibration sensor, which is installed on the pipeline and near the ultrasonic vibration assembly. The vibration sensor is used to monitor the vibration response signal after the ultrasonic vibration propagates and attenuates in the pipeline, so as to determine the blockage in the pipeline.

[0013] The ultrasonic vibration components and monitoring units in the multiple anti-blocking systems are all electrically connected to the control module. The control unit is used to receive signals from the monitoring unit and make corresponding adjustments to the ultrasonic vibration components.

[0014] The pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, includes an ultrasonic vibration component comprising an ultrasonic generator, a transducer, and an amplitude transformer.

[0015] The ultrasonic generator is electrically connected to the transducer to convert current into a high-frequency electrical signal; the transducer is used to convert the high-frequency electrical signal into mechanical vibration; the transducer is connected to the amplitude transformer, which is used to amplify the mechanical vibration output by the transducer.

[0016] In the pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, the ultrasonic vibration component further includes a vibration reinforcing ring, which is sleeved around the pipeline, and the amplitude transformer is coupled to the vibration reinforcing ring.

[0017] In the pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, the monitoring unit includes a first vibration sensor and a second vibration sensor, both of which are installed on the pipeline, wherein the first vibration sensor and the second vibration sensor are respectively located on both sides of the vibration reinforcement ring.

[0018] The pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, includes a first mounting ring and a second mounting ring in the monitoring unit;

[0019] The first mounting ring is fitted around the outside of the pipe, and the first vibration sensor is mounted on the first mounting ring;

[0020] The second mounting ring is fitted around the outside of the pipe, and the second vibration sensor is mounted on the second mounting ring.

[0021] In the pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, the control module includes a microcontroller, a data acquisition unit, and a drive unit, wherein the microcontroller is electrically connected to the data acquisition unit and the drive unit.

[0022] The data acquisition unit is electrically connected to the vibration sensor and is used to acquire vibration response signals and transmit them to the microcontroller.

[0023] The drive unit is electrically connected to the ultrasonic vibration component and is used to transmit an adjustment signal to the ultrasonic vibration component when the microcontroller determines that the pipeline is blocked.

[0024] The pipeline anti-clogging system with vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above is preferably characterized by the control module having three operating modes: standby mode, enhanced anti-clogging mode, and periodic unclogging mode.

[0025] In standby mode, the ultrasonic vibration component operates in standby mode, and the attenuation rate of the vibration response signal monitored by the vibration sensor is within the standby operating range.

[0026] When the vibration response signal attenuation rate detected by the vibration sensor is within the particle deposition range, the control module switches to the enhanced anti-blocking mode and gradually increases the operating parameters of the ultrasonic vibration component according to the set value.

[0027] When the vibration response signal attenuation rate detected by the vibration sensor is within the particle blockage range, the control module switches to the periodic unblocking mode and further increases the operating parameters of the ultrasonic vibration component according to the set value.

[0028] In the pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction described above, preferably, the height of the helical blade is 0.05 to 0.15 times the inner diameter of the pipeline, and the pitch of the helical blade is 0.8 to 1.5 times the inner diameter of the pipeline.

[0029] In the pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, the spiral blades are made of stainless steel, and three spiral blades are provided, with the three spiral blades evenly distributed in the inner sleeve.

[0030] In the pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction as described above, preferably, the inner sleeve is made of one of polyurethane, rubber, weld overlay wear-resistant alloy, or embedded ceramic.

[0031] Compared with the closest prior art, the technical solution of this application has the following beneficial effects:

[0032] In this anti-clogging system, the ultrasonic vibration component is constantly in operation to emit ultrasonic vibrations during the pipeline transportation of tailings slurry. Vibration sensors collect the vibration response signal after the ultrasonic vibration attenuates as it propagates in the pipeline in real time. Vibration sensors in multiple anti-clogging systems send the collected vibration response signals to the control module. The control module can determine whether there is a blockage in the pipeline by comparing and analyzing the vibration attenuation characteristics at different locations. When the vibration response signal of a vibration sensor in a certain anti-clogging system is abnormal, it can be determined that there is a blockage at the pipeline location of the anti-clogging system corresponding to that vibration sensor. This achieves high-precision positioning of the pipeline blockage location and improves the accuracy of monitoring the pipeline operation status.

[0033] After the control module determines that a blockage has occurred in the pipeline corresponding to a certain anti-blocking system, the control module sends an adjustment signal to the ultrasonic vibration component of the anti-blocking system at the corresponding blockage location to increase the specific operating parameters of the ultrasonic vibration component, causing the ultrasonic vibration component to generate greater ultrasonic vibration. Under the action of ultrasonic vibration, the inner sleeve and the spiral blade generate micro-amplitude vibration, inducing cavitation effect in the slurry near the pipeline. The cavitation effect forms micro-bubbles on the surface of the inner sleeve and the spiral blade. The bubbles are periodically generated and burst, thereby reducing the adhesion resistance of the pipe wall and the blade surface, and reducing the transport resistance. At the same time, the spiral blade is used to guide the slurry to form a rotating flow in the pipeline, so that the fluid concentration tends to be uniform along the cross-sectional direction. The two work together to suppress particle deposition, improve the local flow field state, unclog the pipeline, reduce the possibility of pipeline blockage, and improve transport stability.

[0034] The inner sleeve of this anti-clogging system can be installed inside the pipeline without damage, and the ultrasonic vibration component and monitoring unit can be installed outside the pipeline without damage, without changing the original pipeline structure. It is easy to install, highly adaptable, and suitable for anti-clogging and drag reduction applications in pipeline transportation of high solids content slurry and easily deposited materials. Attached Figure Description

[0035] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. Wherein:

[0036] Fig. 1 This is a schematic diagram of the anti-clogging system installed on a pipeline according to some embodiments of this application;

[0037] Fig. 2 This is a schematic diagram of the anti-blocking system provided according to some embodiments of this application;

[0038] Fig. 3 This is a schematic diagram illustrating the working principle of an anti-blocking system provided according to some embodiments of this application.

[0039] Explanation of reference numerals in the attached figures:

[0040] 1. Filling pump; 2. Pipeline; 3. Anti-clogging system; 301. Inner sleeve; 302. Helical blade; 303. Second vibration sensor; 304. Amplitude bar; 305. Ultrasonic generator; 306. Transducer; 307. First vibration sensor; 308. First mounting ring; 309. Vibration reinforcing ring; 310. Second mounting ring; 311. Pipeline outer wall; 4. Valve; 5. Filling tank; 6. Control module; 7. Ground. Detailed Implementation

[0041] The present application will now be described in detail with reference to the accompanying drawings and embodiments. Various examples are provided by way of interpretation and not by way of limitation. In fact, those skilled in the art will recognize that modifications and variations can be made to the present application without departing from the scope or spirit thereof. For example, a feature represented or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, it is desirable that the present application encompass such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0042] In the following description, the terms "first / second / third" are used merely to distinguish similar objects and do not represent a specific order of objects. It is understood that "first / second / third" may be interchanged in a specific order or sequence where permitted, so that the embodiments of this application described herein can be implemented in an order other than that illustrated or described herein.

[0043] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terminology used herein is for the purpose of describing embodiments of this disclosure only and is not intended to limit this disclosure.

[0044] In the description of this application, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and do not require that this application be constructed and operated in a specific orientation, and therefore should not be construed as limiting this application. The terms "connected," "linked," and "set up" used in this application should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; direct connections or indirect connections through intermediate components; wired connections, radio connections, or wireless communication signal connections. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0045] The present application will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present application can be combined with each other.

[0046] According to specific embodiments of this application, such as Figs. 1-3 As shown, this application provides a pipeline anti-clogging system for vibration attenuation positioning and ultrasonic vibration cavitation drag reduction. An anti-clogging system 3 is installed at each easily clogged location on the pipeline 2, and multiple anti-clogging systems 3 are electrically connected to the control module 6. In this embodiment, the easily clogged locations in the pipeline 2 include long straight sections, easily deposited sections, and local pressure drop reversal sections.

[0047] Anti-blocking system 3 includes:

[0048] Inner sleeve 301 is used to be installed inside the pipe 2; that is, the outer wall of the inner sleeve 301 is installed close to the inner wall of the pipe 2 so that the inner sleeve 301 is fixed in the pipe 2.

[0049] The inner wall of the inner sleeve 301 is evenly distributed with multiple spiral blades 302 for guiding flow.

[0050] An ultrasonic vibration assembly is installed on the outer wall of pipe 2, and the installation position of the ultrasonic vibration assembly corresponds to the installation position of the inner sleeve 301. The ultrasonic vibration assembly is used to generate ultrasonic vibration.

[0051] The monitoring unit includes at least one vibration sensor, which is installed on the pipe 2 and near the ultrasonic vibration component. The vibration sensor is used to monitor the vibration response signal after the ultrasonic vibration propagates and attenuates in the pipe 2, so as to determine the blockage in the pipe 2.

[0052] The ultrasonic vibration components and monitoring units in the multiple anti-blocking systems 3 are all electrically connected to the control module 6. The control unit is used to receive signals from the monitoring unit and make corresponding adjustments to the ultrasonic vibration components.

[0053] In this anti-clogging system 3, a spiral blade 302 is installed in the inner sleeve 301 and the inner sleeve 301 is directly installed in the pipe 2. This allows the spiral blade 302 to be installed in the pipe 2 without damage. The spiral blade 302 can guide the fluid movement in the pipe 2 and form a spiral fluid in the pipe 2, which helps to alleviate the local deposition in the pipe 2.

[0054] During the tailings slurry transport process in pipeline 2, the ultrasonic vibration component is constantly in operation, emitting ultrasonic vibrations. Vibration sensors collect the vibration response signal after the ultrasonic vibrations attenuate as they propagate through pipeline 2 in real time; that is, in this embodiment, the vibration sensors are not used to detect the natural vibrations of pipeline 2. Since the vibration response signal attenuates with the propagation distance and the state within pipeline 2, when sediment or blockage occurs within pipeline 2, the local structural stiffness, mass distribution, and energy dissipation characteristics change, leading to abnormal changes in the amplitude, spectrum, or attenuation rate of the vibration response signal. Vibration sensors in multiple anti-blockage systems 3 send the collected vibration response signals to the control module 6. The control module 6 can determine whether there is a blockage in pipeline 2 by comparing and analyzing the vibration attenuation characteristics at different locations. When the vibration response signal of a vibration sensor in a certain anti-blockage system 3 is abnormal, it can be determined that a blockage has occurred at the location of the anti-blockage system 3 in pipeline 2 corresponding to that vibration sensor. This achieves high-precision positioning of the blockage location in pipeline 2 and improves the accuracy of monitoring the operating status of pipeline 2.

[0055] After the control module 6 determines that a blockage has occurred at the location of the pipe 2 corresponding to a certain anti-blocking system 3, the control module 6 sends an adjustment signal to the ultrasonic vibration component of the anti-blocking system 3 at the corresponding blockage location of the pipe 2 to improve the specific operating parameters of the ultrasonic vibration component, so that the ultrasonic vibration component generates greater ultrasonic vibration. Under the action of ultrasonic vibration, the inner sleeve 301 and the spiral blade 302 generate micro-amplitude vibration, and induce cavitation effect in the slurry near the pipe 2. The cavitation effect forms micro bubbles on the surface of the inner sleeve 301 and the spiral blade 302. The bubbles are generated and burst periodically, thereby reducing the adhesion resistance of the pipe wall and the blade surface and reducing the transport resistance. At the same time, the spiral blade 302 is used to guide the slurry to form a rotating flow in the pipe 2, so that the fluid concentration tends to be uniform along the cross-sectional direction, inhibiting particle deposition, improving the local flow field state, realizing the unblocking of the pipe 2, and reducing the possibility of blockage in the pipe 2 and improving the transport stability.

[0056] The inner sleeve 301 in the anti-clogging system 3 can be installed inside the pipe 2 without damage, and the ultrasonic vibration component and monitoring unit can be installed outside the pipe 2 without damage. There is no need to change the original structure of the pipe 2. It is easy to install, highly adaptable, and suitable for anti-clogging and drag reduction applications in the pipeline 2 for conveying high solid content slurry and easily deposited materials.

[0057] The ultrasonic vibration assembly includes an ultrasonic generator, a transducer 306, and an amplitude transformer 304. The ultrasonic generator is electrically connected to the transducer 306 and is used to convert current into a high-frequency electrical signal. The transducer 306 is used to convert the high-frequency electrical signal into mechanical vibration. The transducer 306 is connected to the amplitude transformer 304, which is used to amplify the mechanical vibration output by the transducer 306. In this embodiment, the amplitude transformer 304 contacts the outer wall 311 of the pipe, thereby transmitting the ultrasonic vibration through the outer wall 311 to the inner sleeve 301 and the helical blade 302 in the pipe 2.

[0058] The ultrasonic vibration assembly also includes a vibration reinforcing ring 309, which is sleeved around the outside of the pipe 2, and the amplitude transformer 304 is coupled to the vibration reinforcing ring 309.

[0059] In this embodiment, the vibration reinforcing ring 309 is a circular ring structure. After the vibration reinforcing ring 309 is sleeved around the pipe 2, it can be fixed to the pipe 2 by welding, making the connection between the vibration reinforcing ring 309 and the pipe 2 more secure. Since the entire vibration reinforcing ring 309 is sleeved around the pipe 2, it is easier for the vibration reinforcing ring 309 to uniformly transmit ultrasonic vibration to the pipe 2.

[0060] In this embodiment, a planar boss is machined on the outer surface of the vibration reinforcing ring 309, and the amplitude transformer 304 is coupled to the planar boss of the vibration reinforcing ring 309 to achieve higher vibration transmission efficiency between the amplitude transformer 304 and the vibration reinforcing ring 309. In other embodiments, two symmetrically arranged planar bosses are machined on the outer surface of the vibration reinforcing ring 309, and each of the two planar bosses is coupled to an amplitude transformer 304. In this case, each amplitude transformer 304 is equipped with an ultrasonic generator and a transducer 306.

[0061] The monitoring unit includes a first vibration sensor 307 and a second vibration sensor 303, both of which are installed on the pipe 2. The first vibration sensor 307 and the second vibration sensor 303 are located on both sides of the vibration reinforcing ring 309.

[0062] In this embodiment, the first vibration sensor 307 is located on the periphery of the pipe 2 upstream of the vibration reinforcing ring 309, and the second vibration sensor 303 is located on the periphery of the pipe 2 downstream of the vibration reinforcing ring 309. By using two vibration sensors, the vibration response signal after the ultrasonic vibration has propagated and attenuated in the pipe 2 can be monitored more efficiently.

[0063] The monitoring unit also includes a first mounting ring 308 and a second mounting ring 310; the first mounting ring 308 is sleeved on the outside of the pipe 2, and the first vibration sensor 307 is mounted on the first mounting ring 308; the second mounting ring 310 is sleeved on the outside of the pipe 2, and the second vibration sensor 303 is mounted on the second mounting ring 310.

[0064] In this embodiment, after the first mounting ring 308 and the second mounting ring 310 are fitted around the outside of the pipe 2, they are both connected to the pipe 2 by welding. This arrangement allows the mounting rings to transmit the upward vibration of the entire outer ring of the pipe 2 to the vibration sensor, which is beneficial to improving the monitoring accuracy and monitoring efficiency of the vibration sensor.

[0065] The control module 6 includes a microcontroller, a data acquisition unit, and a drive unit. The microcontroller is electrically connected to the data acquisition unit and the drive unit. The data acquisition unit is electrically connected to the vibration sensor and is used to acquire vibration response signals and transmit them to the microcontroller. The drive unit is electrically connected to the ultrasonic vibration component and is used to transmit adjustment signals to the ultrasonic vibration component when the microcontroller determines that the pipe 2 is blocked.

[0066] The control module 6 has three operating modes: standby mode, enhanced anti-blocking mode, and periodic unblocking mode.

[0067] In standby mode, the ultrasonic vibration component is in standby mode. At this time, the vibration response signal attenuation rate monitored by the vibration sensor is within the standby operation range. At this time, no particle deposition or blockage occurs in the pipe 2. The spiral blades 302 in the inner sleeve 301 can guide the tailings slurry to form a spiral flow field to avoid axial deposition.

[0068] When the vibration response signal attenuation rate detected by the vibration sensor is within the particle deposition range, the control module 6 switches to the enhanced anti-clogging mode and gradually increases the operating parameters of the ultrasonic vibration component according to the set value. At this time, slight particle deposition occurs in the pipe 2, and the ultrasonic vibration component increases the output power to enhance the cavitation effect. In conjunction with the spiral blade 302, the deposited particles are stripped off.

[0069] When the vibration response signal attenuation rate detected by the vibration sensor is within the particle blockage range, the control module 6 switches to the periodic unblocking mode and further increases the operating parameters of the ultrasonic vibration component according to the set value. At this time, severe particle blockage occurs in the pipe 2. The ultrasonic vibration component increases the output power to the maximum and works continuously in pulse mode to increase the cavitation effect. The impact force of the cavitation bubbles breaking up breaks the deposit layer to achieve the unblocking of the blocked pipe 2.

[0070] In this embodiment, the control module 6 adjusts the operating parameters of the ultrasonic vibration component, including the output power, operating frequency and pulse mode of the ultrasonic generator 305, thereby realizing anti-blocking control and flow field optimization in the pipeline 2 transportation process.

[0071] The height of the helical blade 302 is 0.05 to 0.15 times the inner diameter of the pipe 2, and the pitch of the helical blade 302 is 0.8 to 1.5 times the inner diameter of the pipe 2. This arrangement ensures that the helical blade 302 only plays a guiding role near the inner wall of the pipe 2, and does not occupy a large space inside the pipe 2, thus ensuring that the helical blade 302 does not have an excessive impact on the flow rate of the pipe 2.

[0072] The spiral blade 302 is made of stainless steel. There are three spiral blades 302, which are evenly distributed in the inner sleeve 301.

[0073] In this embodiment, the stainless steel material has good corrosion resistance, which allows the spiral blade 302 to better adapt to the acid and alkaline environment of the tailings slurry.

[0074] The inner sleeve 301 is made of one of the following materials: polyurethane, rubber, wear-resistant alloy overlay, or embedded ceramic. In this embodiment, polyurethane, rubber, wear-resistant alloy overlay, or embedded ceramic all have good wear resistance and corrosion resistance, which is beneficial for the application of the inner sleeve 301 in the tailings slurry transportation environment.

[0075] In summary, this pipeline anti-clogging system 3 combines ultrasonic vibration excitation, vibration attenuation monitoring, and adaptive control adjustment to achieve online identification, location, and suppression of blockages in pipeline 2. The vibration attenuation data provided by the monitoring unit gives the control module 6 clear information on the location and development trend of the blockage. The synergistic effect of the ultrasonic vibration component and the flow guidance of the helical blade 302 effectively reduces the conveying resistance and prevents material particle deposition, thereby ensuring the long-term stable operation of pipeline 2 during the conveying process. Furthermore, this pipeline anti-clogging system 3 has the advantages of non-invasive installation, automatic adjustment, and strong adaptability, making it suitable for anti-clogging and resistance reduction control of pipelines 2 conveying high-solids-content slurries and easily deposited materials.

[0076] Based on a DN300 (300mm diameter) tailings slurry transport pipeline 2, the pipeline 2 is connected to the filling pump 1. The pipeline 2 is equipped with valves 4 and multiple anti-clogging systems 3. The tailings slurry is transported through the pipeline 2 to the filling pool 5 below the ground level 7. The following is a detailed description of the specific implementation:

[0077] Example 1:

[0078] In Example 1, for long-distance transportation of high-concentration tailings slurry with a solid content of 60%~70% (transportation distance ≥5km), safe transportation is achieved through the closed-loop control logic of "monitoring-regulation-drag reduction and anti-blocking" of the pipeline anti-blocking system 3.

[0079] Multiple pipeline anti-blocking systems 3 are deployed in three key areas of pipeline 2: the long straight section, the section prone to sedimentation, and the section with local pressure drop and reversal.

[0080] In the monitoring unit of the pipeline anti-clogging system 3, the vibration sensor has a measurement range of 0.1~10kHz, a sensitivity of 100mV / g, and an IP6 protection rating, making it suitable for humid mining conditions. The vibration sensor is installed radially and vertically (at a 90° angle to the axis of pipeline 2), mounted on a mounting ring. The mounting ring is fastened to the outer wall 311 of the pipeline, with the mounting surface of the ring completely in contact with the outer wall 311. Waterproof sealant is applied to the contact area, ensuring effective transmission of the vibration signal (signal attenuation ≤3%) and improving waterproof and dustproof performance. The vibration sensor is connected to the data acquisition unit of the control module 6 via a shielded cable, with a sampling frequency set to 1kHz, transmitting vibration response signal data in real time.

[0081] The ultrasonic vibration assembly consists of a transducer 306, an amplitude transformer 304, and an ultrasonic generator 305. The ultrasonic generator 305 operates at a frequency of 28kHz (preferred to be within the range of 20kHz to 40kHz), with an output power that is continuously adjustable from 0 to 3000W and a power supply voltage of AC380V. The transducer 306 adopts a piezoelectric ceramic stacked structure, and the vibration amplitude can reach 25μm. The amplitude transformer 304 is made of 45# steel and is designed with a stepped structure. The input end has a diameter of 50mm, the output end has a diameter of 30mm, the length is 200mm, the amplitude amplification ratio is 1:3, and the output end amplitude can reach 30μm.

[0082] A Q355B vibration reinforcing ring 309 (compatible with DN300 pipe 2) is fixed to the outer wall 311 of the pipe by circumferential welding. One side of the vibration reinforcing ring 309 has a machined mounting surface (flatness ≤0.02mm) for mounting the amplitude transformer 304. High-temperature resistant silicone grease (0.5~1mm thickness) is applied to the contact surface between the amplitude transformer 304 and the mounting surface to fill the gap and ensure ultrasonic energy transfer efficiency ≥90%. A bolt hole is provided on the mounting surface of the vibration reinforcing ring 309, and another bolt hole is provided at the end of the amplitude transformer 304. The amplitude transformer 304 is connected to the vibration reinforcing ring 309 by stainless steel double-ended bolts with a preload torque of 45 N•m to effectively prevent vibration loosening. Ultrasonic vibration is transmitted through pipe 2 to the inner sleeve 301 and the helical blade 302, achieving drag reduction and uniform flow through induced cavitation.

[0083] The inner sleeve 301 is made of polyurethane wear-resistant material with a thickness of 15mm. It is fitted to the inner wall of pipe 2 with an interference fit (outer diameter of inner lining 300mm, inner diameter of pipe 2 497mm, interference 3mm). The surface roughness of the inner lining Ra≤0.8μm. For harsh wear conditions, it can be replaced with rubber, weld overlay wear-resistant alloy or embedded ceramic materials.

[0084] The spiral blade 302 is made of 2205 duplex stainless steel (corrosion resistant and suitable for acidic and alkaline tailings slurry environments). It has three blades arranged at equal angles of 120°. The blade height is 0.1 times the pipe diameter (50mm), and the pitch is 0.8 times the pipe diameter (400mm). The spiral blade 302 is fixed to the inner wall of the inner sleeve 301. The leading edge of the spiral blade 302 is rounded (R3mm) to avoid localized eddies and guide the tailings slurry to form a stable spiral flow field.

[0085] Control module 6 includes a microcontroller, a data acquisition unit, and a drive unit: the microcontroller is an STM32H743VIT6 (32-bit ARM architecture, 480MHz), the data acquisition unit uses an AD7606 chip (supporting 8-channel synchronous sampling, 200kSPS sampling rate), and the drive unit uses an IR2110 power driver chip. Control module 6 is electrically connected to the vibration sensor and ultrasonic generator, and has adaptive control functionality.

[0086] Control module 6 receives signals from all vibration sensors in real time and determines the blockage status of pipe 2 by calculating the vibration acceleration attenuation rate: when the attenuation rate is <5%, it is considered normal transport, and control module 6 operates in standby mode; when 5% ≤ attenuation rate < 15%, it is considered slight deposition, and control module 6 operates in enhanced anti-blockage mode; when the attenuation rate is ≥15%, it is considered severe blockage and blockage location is required, and control module 6 operates in periodic unblocking mode. Blockage location is achieved by comparing the abrupt changes in attenuation rate of adjacent sensors, which can accurately pinpoint the blockage area with a location error ≤10m.

[0087] The workflow of the pipeline anti-clogging system 3 is as follows: After the system is powered on, the control module 6 completes initialization, the ultrasonic generator 305 starts at 28kHz and 1300W power, and the spiral blade 302 guides the tailings slurry to form a spiral flow field to avoid axial deposition; at this time, the control module 6 is in standby mode.

[0088] When a vibration sensor detects slight deposition (5% ≤ attenuation rate < 15%), the control module 6 switches to the enhanced anti-blocking mode, increasing the ultrasonic power of the ultrasonic generator at the corresponding location to 2300W and fine-tuning the frequency to 30kHz to enhance the cavitation effect and achieve the initial deposition particle removal.

[0089] When a vibration sensor detects severe blockage (attenuation rate ≥15%), the control module 6 switches to the periodic unblocking mode, and adjusts the ultrasonic generator at the corresponding location to a pulse mode of "3s high power (3000W) + 2s intermittent" for 5 minutes to break the deposit layer through the impact force of cavitation bubble rupture.

[0090] The technical effects of this embodiment are significant: the anti-clogging rate of tailings slurry reaches 92%, and the clogging frequency is reduced from once per week in the traditional solution to once every 2 months; the conveying resistance is reduced by 18%, and the pump energy consumption is reduced by 15%; and the non-invasive installation method does not require damage to the pipeline 2, so the installation time of the pipeline anti-clogging system 3 is ≤8 hours / km, which greatly improves the installation efficiency and can meet the needs of actual engineering applications.

[0091] Example 2:

[0092] This embodiment, based on Embodiment 1, optimizes the installation structure and control logic of the ultrasonic vibration component to improve the uniformity of ultrasonic energy distribution and the precision of adjustment. Two symmetrical mounting planes are machined on the outer side of the vibration reinforcing ring 309. These two mounting planes are symmetrically arranged around the axis of the vibration reinforcing ring 309. Each plane is equipped with one set of amplitude transformers 304 and an ultrasonic generator 305, forming bidirectional ultrasonic coupling. This allows ultrasonic energy to cover the entire cross-section of the pipe 2, improving the uniformity of cavitation effect by 40%. The corresponding ultrasonic vibration propagation path is as follows: the two sets of ultrasonic generators 305 generate vibrations synchronously, which are amplified by their respective amplitude transformers 304 and then radially transmitted from both sides of the pipe 2 to the vibration reinforcing ring 309. The vibrations then penetrate through the pipe 2 wall to the lining and blades. The two sets of vibrations superimpose in the central region of the pipe 2 cross-section, increasing the distribution density of cavitation bubbles within the pipe 2 by 50% and achieving an energy coverage efficiency of 95%, further enhancing the drag reduction and anti-clogging effect.

[0093] The working modes of the pipeline anti-clogging system 3 are as follows:

[0094] When the vibration sensor detects that the vibration response signal attenuation rate is in the range of 5% to 10%, the control module 6 is in standby mode, and the ultrasonic generator adopts a combination of 28kHz frequency and 2000W power.

[0095] When the vibration sensor detects that the vibration response signal attenuation rate is in the range of 10%~15%, the control module 6 is in enhanced anti-blocking mode, and the ultrasonic generator adopts a combination of frequency 32kHz + power 2300W.

[0096] When the vibration sensor detects that the vibration response signal attenuation rate is ≥15%, the control module 6 enters the periodic unblocking mode, and the ultrasonic generator adopts a pulse mode with a frequency of 35kHz and a power of 3000W to achieve adaptive optimization of ultrasonic parameters.

[0097] The rest of the structure in this embodiment is the same as in embodiment 1, but the blockage location response time is shortened to 0.5s and the anti-blockage rate is increased to 95%.

[0098] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction, characterized in that, An anti-clogging system is installed at each easily clogged location on the pipeline, and multiple anti-clogging systems are electrically connected to the control module. The anti-blocking system includes: Inner sleeve, the inner sleeve being installed inside the pipe; Helical blades: Multiple helical blades are evenly distributed on the inner wall of the inner sleeve for guiding flow; An ultrasonic vibration assembly is installed on the outer wall of the pipe, and the installation position of the ultrasonic vibration assembly corresponds to the installation position of the inner sleeve. The ultrasonic vibration assembly is used to generate ultrasonic vibration. The monitoring unit includes at least one vibration sensor, which is installed on the pipeline and near the ultrasonic vibration assembly. The vibration sensor is used to monitor the vibration response signal after the ultrasonic vibration propagates and attenuates in the pipeline, so as to determine the blockage in the pipeline. The ultrasonic vibration components and monitoring units in the multiple anti-blocking systems are all electrically connected to the control module. The control unit is used to receive signals from the monitoring unit and make corresponding adjustments to the ultrasonic vibration components. The control module has three working modes: standby mode, enhanced anti-blocking mode, and periodic unblocking mode. In standby mode, the ultrasonic vibration component operates in standby mode, and the attenuation rate of the vibration response signal monitored by the vibration sensor is within the standby operating range. When the vibration response signal attenuation rate detected by the vibration sensor is within the particle deposition range, the control module switches to the enhanced anti-blocking mode and gradually increases the operating parameters of the ultrasonic vibration component according to the set value. When the vibration response signal attenuation rate detected by the vibration sensor is within the particle blockage range, the control module switches to the periodic unblocking mode and further increases the operating parameters of the ultrasonic vibration component according to the set value.

2. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to claim 1, characterized in that, The ultrasonic vibration assembly includes an ultrasonic generator, a transducer, and an amplitude transformer. The ultrasonic generator is electrically connected to the transducer to convert current into a high-frequency electrical signal; the transducer is used to convert the high-frequency electrical signal into mechanical vibration; the transducer is connected to the amplitude transformer, which is used to amplify the mechanical vibration output by the transducer.

3. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to claim 2, characterized in that, The ultrasonic vibration assembly also includes a vibration reinforcing ring, which is sleeved around the outside of the pipe, and the amplitude transformer is coupled to the vibration reinforcing ring.

4. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to claim 3, characterized in that, The monitoring unit includes a first vibration sensor and a second vibration sensor, both of which are installed on the pipeline, with the first vibration sensor and the second vibration sensor located on opposite sides of the vibration reinforcement ring.

5. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to claim 4, characterized in that, The monitoring unit further includes a first mounting ring and a second mounting ring; The first mounting ring is fitted around the outside of the pipe, and the first vibration sensor is mounted on the first mounting ring; The second mounting ring is fitted around the outside of the pipe, and the second vibration sensor is mounted on the second mounting ring.

6. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to claim 5, characterized in that, The control module includes a microcontroller, a data acquisition unit, and a drive unit, and the microcontroller is electrically connected to the data acquisition unit and the drive unit. The data acquisition unit is electrically connected to the vibration sensor and is used to acquire vibration response signals and transmit them to the microcontroller. The drive unit is electrically connected to the ultrasonic vibration component and is used to transmit an adjustment signal to the ultrasonic vibration component when the microcontroller determines that the pipeline is blocked.

7. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to any one of claims 1-6, characterized in that, The height of the helical blade is 0.05 to 0.15 times the inner diameter of the pipe, and the pitch of the helical blade is 0.8 to 1.5 times the inner diameter of the pipe.

8. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to claim 7, characterized in that, The spiral blades are made of stainless steel, and there are three spiral blades, which are evenly distributed in the inner sleeve.

9. The pipeline anti-clogging system based on vibration attenuation positioning and ultrasonic vibration cavitation drag reduction according to any one of claims 1-6, characterized in that, The inner sleeve is made of one of the following materials: polyurethane, rubber, wear-resistant alloy for welding, or embedded ceramic.

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