Scraper type cleaning device for acid water pipeline

Abstract

The invention relates to the technical field of pipeline maintenance equipment, in particular to a scraper type cleaning device for an acid water pipeline, which comprises a tool bit assembly, a connecting rod and a driving mechanism, and further comprises a quick connector, the tool bit assembly comprises four scrapers uniformly distributed along the circumferential direction, and each scraper comprises a mounting part fixedly connected with the outer wall of the connecting rod; the scraping part extends in the axis direction of the connecting rod from the tail end of the mounting part, a scraping working face inclined relative to the axis of the connecting rod is formed on the scraping part, a scraping blade is formed on the edge of the scraping working face, a sawtooth-shaped structure is arranged on the scraping blade, one end of the connecting rod is fixedly connected with the cutter head assembly, and the other end of the connecting rod is fixedly connected with the cutter head assembly. The other end of the connecting rod is connected with the driving mechanism through a quick connector; the included angle between the working face of the scraper and the axis is 45 degrees, the edge of the scraper is provided with a sawtooth-shaped structure, automatic feeding of cleaning operation is achieved, the pure mechanical cleaning principle is adopted, the safety risk of making contact with residual acid liquor is thoroughly avoided, and the scraper can be adapted to various common pipe diameters.

Description

Technical Field

[0001] This invention relates to the field of pipeline maintenance equipment technology, and in particular to a scraper-type cleaning device for acid water pipelines. Background Technology

[0002] In fields such as acid water treatment, acid water pipelines transport acidic media (such as sulfuric acid and hydrochloric acid) for a long time. Their inner walls are prone to hard scale, corrosion product layers and sticky impurities due to acid corrosion and the deposition of impurities in the medium. This leads to a reduction in the pipeline's cross-sectional area and a decrease in transport efficiency. In severe cases, it can cause pipeline blockage and corrosion perforation, affecting the continuity of production and posing safety hazards.

[0003] Existing methods for cleaning acid water pipelines have many drawbacks: high-pressure water flushing relies on the impact of high-pressure media, which has limited effectiveness in removing stubborn scale and corrosion products, and the high-pressure water flow can easily aggravate corrosion damage to the inner wall of the pipeline, causing secondary damage; chemical cleaning requires the use of special descaling agents, which is not only costly, but also generates a large amount of acid- and chemical-containing wastewater, causing secondary pollution, and the agents pose an additional risk of corrosion to the pipeline base material; manual mechanical cleaning relies on operators manually operating tools, which is inefficient, and the internal environment of acid water pipelines is harsh, making it easy for operators to come into contact with acid residues and cause safety accidents, and it is also difficult to adapt to the cleaning needs of pipelines with different diameters, bends and long distances.

[0004] Therefore, in view of the existing acid water pipeline cleaning devices, which are characterized by low efficiency, poor corrosion resistance, insufficient environmental protection, and weak versatility, a scraper-type cleaning device for acid water pipelines can be designed to achieve efficient and thorough removal of impurities from the inner wall of acid water pipelines. At the same time, it has the advantages of corrosion and wear resistance, safe operation, green environmental protection, and compatibility with various pipe diameters, thereby reducing pipeline maintenance costs and extending pipeline service life. Summary of the Invention

[0005] In order to overcome the problems of low efficiency, poor corrosion resistance, insufficient environmental protection and weak versatility of existing acid water pipeline cleaning devices.

[0006] The technical solution of the present invention is as follows: a scraper-type cleaning device for acid water pipelines, comprising a blade assembly, a connecting rod, and a drive mechanism, and further comprising a quick connector. The blade assembly comprises four scrapers evenly distributed along the circumferential direction. Each scraper comprises a mounting part fixedly connected to the outer wall of the connecting rod, and a scraping part extending from the end of the mounting part along the axis of the connecting rod. The scraping part forms a scraping working surface inclined relative to the axis of the connecting rod. The edge of the scraping working surface constitutes a scraping blade, and the scraping blade is provided with a serrated structure. One end of the connecting rod is fixedly connected to the blade assembly, and the other end is connected to the drive mechanism through a quick connector. The surface of the connecting rod is provided with scale markings.

[0007] Preferably, during operation, the drive mechanism is activated, and its power is transmitted to the cutter head assembly via the connecting rod. A quick-connect coupling enables rapid and reliable connection and torque transmission between the connecting rod and the drive mechanism. The drive mechanism drives the connecting rod and the cutter head assembly fixedly connected to it to rotate together. During rotation, four scrapers evenly distributed along the circumference of the cutter head assembly unfold outwards under centrifugal force. Each scraper is securely fixed to the outer wall of the connecting rod via its mounting portion, ensuring structural stability. The scraping portion of the scraper extends along the axial direction of the connecting rod and enters the pipe interior. Each scraping portion of the scraper forms a shape inclined relative to the axis of the connecting rod. The scraping working surface has its edge forming the scraping blade. This inclined design allows the force exerted by the scraping blade on the inner wall of the pipe to be decomposed into circumferential scraping force and axial thrust force when the scraper rotates. The axial thrust force propels the entire device to move forward autonomously along the pipe axis, achieving automatic feeding without the need for external thrust. The serrated structure on the scraping blade can more effectively gnaw, break, and peel off hard scale and corrosion products on the inner wall of the pipe during the rotational scraping process, significantly improving cleaning efficiency. At the same time, the operator can use the scale marks on the surface of the connecting rod to accurately control and monitor the depth of the device inserted into the pipe, ensuring the accuracy and controllability of the cleaning operation.

[0008] Preferably, the scraper is made of 316L stainless steel and has a tungsten carbide wear-resistant coating on its surface, with a thickness of 0.8-1.2mm.

[0009] Preferably, the tooth height of the serrated structure is 3-5 mm and the tooth pitch is 8-10 mm.

[0010] Preferably, the connecting rod is a seamless stainless steel tube with a diameter of φ20mm, and its surface is anodized to form an oxide film of 0.1-0.2mm.

[0011] Preferably, the connecting rod is 1315mm long, and the cleaning device includes one or more connecting rods connected to each other via quick connectors.

[0012] Preferably, the drive mechanism includes a connecting seat and a rotating output shaft passing through it. One end of the output shaft forms a power input end for connecting an external motor, and the other end is detachably connected to a quick connector. The power input end is a standard interface for connecting the output shaft of an external electric or pneumatic rotary motor, and can adjust the output torque of the motor in the range of 0-50 N·m and the output speed in the range of 0-300 rpm.

[0013] Preferably, the size of the cutter head assembly is interchangeable to accommodate pipes with inner diameters from DN50 to DN200.

[0014] Preferably, the accuracy of the scale markings is 1 mm.

[0015] Preferably, the extension direction of the scraping blade forms an angle α with the axis of the connecting rod, and the angle α is 45°.

[0016] Preferably, the quick coupling is a stainless steel sealed quick coupling.

[0017] The beneficial effects of this invention are as follows: It adopts a four-blade symmetrical scraper structure, with the scraper working surface at a 45° angle to the axis and serrated edges. During operation, the scraper provides comprehensive circumferential scraping force and stable axial propulsion force, achieving autonomous feeding during cleaning. Actual testing shows that the average cleaning time for a single meter of DN100 pipe is no more than 2 minutes, the internal scale removal rate exceeds 98%, and the pipe flow efficiency after cleaning can be restored to over 95% of its initial state. This represents an efficiency improvement of more than 8 times compared to traditional manual cleaning methods. It also exhibits outstanding corrosion and wear resistance. The scraper body is made of 316L acid-resistant stainless steel, with a 0.8-1.2mm thick tungsten carbide wear-resistant coating applied via plasma spraying. The connecting rod uses a φ20mm seamless stainless steel pipe and undergoes anodizing to form a protective film. Durability testing was conducted in a 5% sulfuric acid environment, and the device's continuous working life exceeds 1000 hours. After hours, key components remained in good working order, significantly reducing the frequency of equipment maintenance and replacement. The operation is safe and environmentally friendly, employing a purely mechanical cleaning principle that eliminates the need for any chemical cleaning agents, thus avoiding the generation of acidic or chemically-containing wastewater and meeting green production requirements. Furthermore, the cleaning operation is entirely performed outside the pipeline, eliminating the need for operators to enter the pipe and completely avoiding the safety risks of contact with residual acid, ensuring the personal safety of operators. The device is highly versatile and economical; by changing the cutter head assemblies of different diameters, it can be adapted to various common pipe diameters ranging from DN50 to DN200. A single drive mechanism combined with multiple cutter heads can meet most working conditions, avoiding the high cost of configuring dedicated equipment for different pipe diameters. It demonstrates comprehensive advantages in acid water pipeline cleaning operations, including high efficiency, durability, safety, and economy, effectively extending pipeline lifespan and reducing maintenance costs. Attached Figure Description

[0018] Figure 1 The diagram shown is a first perspective view of the scraper-type cleaning device for acid water pipes according to the present invention. Figure 2 The diagram shown is a second perspective view of the scraper-type cleaning device for acid water pipes according to the present invention. Figure 3 The diagram shown is a third perspective view of the scraper-type cleaning device for acid water pipes according to the present invention. Figure 4 The diagram shown is a three-dimensional structural schematic of the blade assembly in the scraper-type cleaning device for acid water pipes of the present invention. Figure 5 The diagram shown is a three-dimensional structural diagram of the scraper in the scraper-type cleaning device for acid water pipelines of the present invention.

[0019] Explanation of reference numerals in the attached drawings: 1. Cutter head assembly; 11. Scraper; 111. Mounting part; 112. Scraping part; 113. Scraping blade; 114. Serrated structure; 2. Connecting rod; 3. Drive mechanism; 31. Connecting seat; 32. Power input end; 4. Quick connector; 5. Scale markings. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] Please see Figures 1-5 The present invention provides an embodiment of a scraper-type cleaning device for acid water pipes, comprising a blade assembly 1, a connecting rod 2, and a drive mechanism 3, and further comprising a quick connector 4. The blade assembly 1 comprises four scrapers 11 evenly distributed along the circumference. Each scraper 11 comprises a mounting portion 111 fixedly connected to the outer wall of the connecting rod 2, and a scraping portion 112 extending from the end of the mounting portion 111 along the axial direction of the connecting rod 2. The scraping portion 112 forms a scraping working surface inclined relative to the axial direction of the connecting rod 2. The edge of the scraping working surface forms a scraping blade 113, and the scraping blade 113 is provided with a serrated structure 114. One end of the connecting rod 2 is fixedly connected to the blade assembly 1, and the other end is connected to the drive mechanism 3 through the quick connector 4. The surface of the connecting rod 2 is provided with scale markings 5.

[0022] The scraper 11 is made of 316L stainless steel and has a tungsten carbide wear-resistant coating on its surface. The thickness of the tungsten carbide wear-resistant coating is 0.8-1.2mm. Through the dual protection of the material and the coating, the scraper 11 has excellent corrosion resistance in strong acid environments. The high hardness and wear resistance provided by the tungsten carbide coating 13 significantly extend the working life of the scraping part 112 and reduce the cost of frequent replacement and maintenance due to wear.

[0023] The tooth height of the serrated structure 114 is 3-5 mm and the tooth pitch is 8-10 mm. The serrated structure 114 forms a highly efficient micro-crushing unit on the scraping edge 113, which can cut into and tear hard scale layers like a file, greatly enhancing the initial crushing ability and peeling efficiency of the scraping part 112, and is particularly suitable for processing corrosion products with strong adhesion.

[0024] The connecting rod 2 is a seamless stainless steel tube with a diameter of φ20mm. Its surface is anodized to form an oxide film of 0.1-0.2mm. This ensures that the connecting rod 2 has sufficient torsional strength, while the dense oxide film on its surface can effectively resist acid penetration and corrosion, thus ensuring the stability of power transmission and the long-term durability of the rod under harsh working conditions.

[0025] The connecting rod 2 is 1315mm long. The cleaning device includes one or more connecting rods 2, which are connected by quick connectors 4. This provides standardized modular extension capabilities. Multiple connecting rods 2 can be flexibly spliced ​​together through quick connectors 4, which can quickly adapt to different cleaning needs from short-distance maintenance to pipelines tens of meters long, greatly improving the versatility and operating range of the device.

[0026] The drive mechanism 3 includes a connecting seat 31 and a rotating output shaft passing through it. One end of the output shaft forms a power input end 32 for connecting an external motor, and the other end is detachably connected to a quick connector 4. The power input end 32 is a standard interface for connecting the output shaft of an external electric or pneumatic rotary motor, and can adjust the output torque of the motor within the range of 0-50 N·m and the output speed within the range of 0-300 rpm, making the drive mechanism 3 a universal and adjustable power adaptation platform. The connecting seat 31 and the quick connector 4 can be quickly installed and removed. The wide range of parameter adjustment capability of the power input end 32 allows the operator to accurately match the scraping force and speed according to the hardness of the scale, optimize the cleaning effect and protect the pipeline.

[0027] The size of the cutter head assembly 1 is interchangeable to adapt to pipes with inner diameters from DN50 to DN200. By providing a series of cutter head assemblies 1, a single drive system can cover a variety of pipe specifications commonly found in the chemical industry. This modular design avoids the investment of purchasing special equipment for different pipe diameters, and significantly improves the overall economy and utilization rate of the equipment.

[0028] The accuracy of scale mark 5 is 1mm, providing the operator with a precise depth reference. During cleaning operations, combined with the known angle of scraping blade 113, millimeter-level control of cleaning depth and position can be achieved. This is crucial for avoiding excessive scraping that could damage the pipe wall and for implementing precise point cleaning.

[0029] The extension direction of the scraping blade 113 forms an angle α with the axis of the connecting rod 2. The angle α is 45°. When the scraper 11 rotates, the 45° scraping blade 113 efficiently decomposes the rotational force into circumferential scraping force and axial propulsion force, so that the device can automatically move along the pipeline without external pushing, which greatly reduces the operating intensity and improves the continuity of operation.

[0030] Quick connector 4 is a stainless steel sealed quick connector. It not only greatly improves the assembly and replacement efficiency between the cutter head assembly 1, connecting rod 2 and drive mechanism 3 through quick plug-in and plug-out function, but its stainless steel material and built-in sealing structure also ensure reliable sealing at the connection in acidic environment, effectively preventing media leakage and corrosion of internal threads or structure.

[0031] This embodiment uses the cleaning of a 15-meter-long industrial sulfuric acid transport pipeline with an inner diameter of DN100 and a nominal diameter of 100mm as an example to demonstrate the specific application of the present invention.

[0032] The steps for performing the work are as follows: 1. Preparations before the assignment The pipeline to be cleaned is made of 316L stainless steel and has been transporting sulfuric acid media with a concentration of 8% for a long time. A mixed scale layer with an average thickness of about 4mm has formed on its inner wall. Its main components are sulfate crystals and corrosion products, which has caused the flow rate to drop by about 35%. Before the cleaning operation begins, the upstream and downstream valves of the pipeline are closed first, and the residual acid in the pipeline is safely discharged into the neutralization tank through the drain valve. Then, clean water is injected for low-pressure flushing to remove floating acid and loose impurities from the inner wall, creating a safe and clean initial environment for mechanical cleaning. 2. Equipment selection and assembly Based on the pipe's inner diameter, a cutter head assembly 1 suitable for a DN100 pipe diameter is selected. This assembly includes four scraper blades 11, with a maximum rotation diameter of 98mm for the scraping section 112. The tooth height of the serrated structure 114 on the scraping blade 113 is 4mm, and the tooth pitch is 9mm. The scraper blades 11 use a 316L stainless steel base, with a tungsten carbide wear-resistant coating 13 of approximately 1.0mm thickness plasma-sprayed on the surface to ensure corrosion and wear resistance. Two connecting rods 2 with a standard length of 1315mm are selected. These connecting rods 2 are φ20mm seamless stainless steel pipes with a dense oxide layer formed by anodizing. The rod body is printed with a scale mark 5 with an accuracy of 1mm. First, the mounting part 111 of the cutter head assembly 1 is fixedly connected to the end of the first connecting rod 2 by argon arc welding. Then, the two connecting rods 2 are connected and extended by using quick connector 4, with a total length of about 2.6 meters, which is enough to cover a cleaning section. Finally, the end connecting rod 2 is reliably connected to the connecting seat 31 of the drive mechanism 3 through another quick connector 4. The power input end 32 of the drive mechanism 3 is connected to an external pneumatic rotary motor, and the output torque is preset to 35N·m and the speed is 120rpm through its control panel. 3. Cleaning process The operator holds the drive mechanism 3 and inserts the assembled device through the pipe manhole, so that the cutter head assembly 1 reaches the pipe end. The pneumatic motor is started, and the power is transmitted to the connecting seat 31 through the power input end 32, and then drives the cutter head assembly 1 to rotate at high speed through the connecting rod 2. The working principle and the coordination of each part are as follows: Rotation and scraping: The drive mechanism 3 provides rotational power, which is transmitted to the cutter head assembly 1 through the connecting rod 2. Under the action of centrifugal force, the scraping working surface of the four scraper blades 11 12 is closely attached to the inner wall of the pipe. The serrated structure 114 on the scraping blade 113 is like a miniature planer, which efficiently bites and breaks the hard scale layer. Autonomous feeding: The key design is that the extension direction of the scraping blade 113 forms a 45° angle α with the axis of the connecting rod 2. This causes the rotating scraping working surface to generate a continuous axial component force, i.e., a propulsive force. Under the action of this force, the entire device automatically and uniformly propels inward along the pipeline axis, realizing "autonomous feeding". No external thrust is required. The operator only needs to hold the drive mechanism 3 steady and control the direction. Deep monitoring and extension: Operators can monitor the depth of the device entering the pipeline in real time by observing the scale mark 5 exposed on the connecting rod 2. When the first section of the connecting rod 2 is about to be fully inserted, the operation is paused, the quick connector 4 is disconnected, a new connecting rod 2 is connected, and the operation continues. In this way, the pipeline up to 15 meters long is cleaned section by section. Debris handling and sealing protection: The scraped scale debris is flushed away by the trace amount of liquid remaining in the pipeline during the device's movement. Throughout the operation, the quick joints 4 between the connecting rods 2 and between the connecting rods 2 and the drive mechanism 3 play a reliable sealing role, effectively preventing corrosive media from seeping into the threads or connection gaps and protecting the internal structure. 4. Post-work processing and results After cleaning, turn off the power, remove the device from the pipe in sections, check the scraper 11, its tungsten carbide wear-resistant coating 13 is intact, and the serrated structure 114 is free from chipping or breakage. After cleaning the attached debris, the device can be stored for later use.

[0033] After endoscopic inspection and flow meter calibration, the scale removal rate of the inner wall of the pipeline was greater than 99%, the inner surface was smooth and the roughness was significantly reduced. After the pipeline was restored to fluid flow, the flow rate was fully restored to the design value and the system operating pressure decreased. The total cleaning operation took about 45 minutes, which is more than 10 times more efficient than traditional manual cleaning. Moreover, no chemical agents were used and no secondary wastewater was generated. The pipeline blockage and efficiency reduction problem was solved safely, efficiently and environmentally.

[0034] Through the above steps, a four-blade symmetrical scraper 11 structure is adopted. The working surface of the scraper 11 forms a 45° angle with the axis and has a serrated edge 114. During operation, the scraper 11 provides comprehensive circumferential scraping force and stable axial propulsion force when rotating, realizing autonomous feeding of the cleaning operation. Actual testing shows that the average cleaning time for a single meter of DN100 pipe is no more than 2 minutes, the scale removal rate on the inner wall exceeds 98%, and the pipe flow efficiency after cleaning can be restored to more than 95% of the initial state. This is more than 8 times more efficient than traditional manual cleaning methods. The scraper 11 has outstanding corrosion resistance and wear resistance. The scraper 11 body is made of 316L acid-resistant stainless steel, and the surface is plasma-sprayed with a 0.8-1.2mm thick tungsten carbide wear-resistant coating. The connecting rod 2 is made of φ20mm seamless stainless steel pipe and is anodized to form a protective film. Durability tests were conducted in a 5% sulfuric acid medium environment. After the device has been in continuous operation for more than 1000 hours, the key components still maintain good working condition. This device significantly reduces the frequency of equipment maintenance and replacement. The operation is safe and environmentally friendly, employing a purely mechanical cleaning principle that eliminates the need for any chemical cleaning agents, thus avoiding the generation of acidic or chemically-containing wastewater and meeting green production requirements. Furthermore, the cleaning operation is entirely performed outside the pipeline, eliminating the need for operators to enter the pipe and completely avoiding the safety risks of contact with residual acid, ensuring the personal safety of operators. The device is highly versatile and economical; by changing the cutter head assembly 1 to different diameters, it can adapt to various common pipe diameters ranging from DN50 to DN200. A single drive mechanism 3, combined with multiple cutter heads, can meet most working conditions, avoiding the high cost of configuring dedicated equipment for different pipe diameters. It demonstrates comprehensive advantages in acid water pipeline cleaning operations, including high efficiency, durability, safety, and economy, effectively extending pipeline lifespan and reducing maintenance costs. This addresses the problems of low efficiency, poor corrosion resistance, insufficient environmental friendliness, and weak versatility found in existing acid water pipeline cleaning devices.

[0035] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A scraper-type cleaning device for acid water pipelines, comprising a blade assembly (1), a connecting rod (2), and a drive mechanism (3), characterized in that: It also includes a quick connector (4), and the cutter head assembly (1) includes four scrapers (11) evenly distributed in the circumferential direction. The scraper (11) includes a mounting part (111) fixedly connected to the outer wall of the connecting rod (2), and a scraping part (112) extending from the end of the mounting part (111) along the axis of the connecting rod (2). The scraping part (112) forms a scraping working surface that is inclined relative to the axis of the connecting rod (2). The edge of the scraping working surface constitutes a scraping blade (113). The scraping blade (113) is provided with a serrated structure (114). One end of the connecting rod (2) is fixedly connected to the cutter head assembly (1), and the other end is connected to the drive mechanism (3) through the quick connector (4). The surface of the connecting rod (2) is provided with scale marks (5).

2. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The scraper (11) is made of 316L stainless steel. The scraper (11) has a tungsten carbide wear-resistant coating on its surface. The thickness of the tungsten carbide wear-resistant coating is 0.8-1.2mm.

3. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The tooth height of the serrated structure (114) is 3-5 mm and the tooth pitch is 8-10 mm.

4. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The connecting rod (2) is a seamless stainless steel tube with a diameter of φ20mm. Its surface is anodized to form an oxide film of 0.1-0.2mm.

5. A scraper-type cleaning device for acid water pipelines according to claim 1 or 4, characterized in that: The connecting rod (2) is 1315mm long. The cleaning device includes one or more connecting rods (2), which are connected to each other by quick connectors (4).

6. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The drive mechanism (3) includes a connecting seat (31) and a rotating output shaft passing through it. One end of the output shaft forms a power input end (32) for connecting an external motor, and the other end is detachably connected to a quick connector (4). The power input end (32) is a standard interface for connecting the output shaft of an external electric or pneumatic rotary motor and can adjust the output torque of the motor in the range of 0-50 N·m and the output speed in the range of 0-300 rpm.

7. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The size of the cutter head assembly (1) is interchangeable to fit pipes with inner diameters from DN50 to DN200.

8. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The accuracy of the scale mark (5) is 1 mm.

9. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The extension direction of the scraping blade (113) forms an angle α with the axis of the connecting rod (2), and the angle α is 45°.

10. A scraper-type cleaning device for acid water pipelines according to claim 1, characterized in that: The quick coupling (4) is a stainless steel sealed quick coupling.

Images