Soldering flux recovery system

Abstract

The invention discloses a welding flux recovery system, which belongs to the technical field of welding equipment and comprises a cyclone separator, a gas ejector and a welding flux recovery pipe. The cyclone separator comprises a feeding pipe, a dust discharging opening and a discharging opening located in the bottom, and the discharging opening is used for being connected with a welding flux bin. The gas ejector comprises an ejection opening, a gas inlet and a material suction opening, the ejection opening is connected with the feeding pipe in a sealed mode, the gas inlet is used for being connected with compressed gas supply equipment, and the material suction opening is connected with the welding flux recycling pipe. In the welding process, the gas jet device can provide negative pressure as power for the welding flux recovery pipe, redundant welding flux at the welding seam is sucked into the cyclone separator to be purified, the purified welding flux falls into the welding flux bin under the gravity settling effect to be recycled, material loss is reduced, and welding flux waste is avoided.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and in particular to a flux recovery system. Background Technology

[0002] Narrow-gap submerged arc welding (NGA) systems are particularly suitable for automated welding of large annular pipelines, such as the precision welding of annular components like nuclear power plant main steam pipelines and chemical pressure pipelines. This system uses a three-axis movement mechanism to drive an ultra-thin welding torch along the annular seam of the pipeline to achieve narrow-gap (14mm~18mm) welding. Combined with a pipeline rotation mechanism, this ensures the welding torch remains in the optimal position throughout the annular welding process. During welding, solder is continuously fed from the solder bin to the weld seam. A large amount of excess solder is generated during the welding process, and current NGA systems rarely recycle this excess solder, resulting in waste. Summary of the Invention

[0003] The purpose of this invention is to solve the above-mentioned technical problems and provide a flux recovery system. During the welding process, the gas jet injector can provide negative pressure to the flux recovery pipe to draw excess flux from the weld into the cyclone separator for purification. The purified flux falls into the flux bin under the action of gravity for recycling, reducing material loss and avoiding flux waste.

[0004] To achieve the above objectives, the present invention provides the following solution: The present invention discloses a flux recovery system, including a cyclone separator, a gas jet injector, and a solder recovery pipe; the cyclone separator includes an inlet pipe, a dust outlet, and an outlet located at the bottom, the outlet being connected to a solder bin, and a screen being provided between the outlet and the solder bin; the gas jet injector includes an ejection port, an air inlet, and a suction port, the ejection port being sealed to the inlet pipe, the air inlet being connected to a compressed gas supply device, and the suction port being connected to the solder recovery pipe.

[0005] Preferably, the cyclone separator further includes a main housing and a separation tube. The top wall of the main housing is provided with an inlet, the side wall of the main housing has a circular cross-section, and the bottom wall of the main housing is provided with a discharge port. The inlet of the separation tube extends into the main housing through the inlet. The separation tube is sealed and fixedly connected to the inlet, and an annular separation chamber is formed between the separation tube and the main housing. The inlet of the separation tube is close to the discharge port, the screen is disposed on the discharge port, and the outlet of the separation tube is located above the main housing, constituting the dust discharge port. The feed pipe communicates with the separation chamber, and the axis of the feed pipe is tangent to the cross-section of the side wall of the main housing.

[0006] Preferably, the solder recovery pipe includes a recovery hose and a recovery rigid pipe. The outlet of the recovery hose is connected to the suction port, the inlet of the recovery hose is connected to the outlet of the recovery rigid pipe, and the recovery rigid pipe is fixedly connected to the solder bin by a rigid pipe mounting bracket. The inlet of the recovery rigid pipe is arranged downward and close to the flux recovery area.

[0007] Preferably, the recovery rigid pipe includes a suction section and a transition section arranged sequentially from the inlet to the outlet. The suction section has a rectangular cross-section. The transition section is connected to the recovery hose, and the recovery hose has a circular cross-section. The cross-section of the transition section gradually transitions from rectangular to circular from one end near the transition section to the other end.

[0008] Preferably, the inlet of the recovery tube is equipped with a filter plate.

[0009] Preferably, the gas ejector includes an ejector tube and a nozzle. The ejector tube includes a straight section and an inclined section. The inlet of the inclined section is connected to the solder recovery tube, which forms the suction port. The outlet of the inclined section is connected to the inlet of the straight section. The outlet of the straight section is coaxially connected to the feed tube, which forms the ejector outlet. The inlet of the nozzle is used to connect to a compressed gas supply device, which forms the air inlet. The outlet of the nozzle communicates with the inclined section. The nozzle is coaxially arranged with the straight section, and the outlet of the nozzle extends to the inlet of the straight section. There is an obtuse angle between the straight section and the inclined section.

[0010] Preferably, the inclined tube section is provided with a threaded seat, and the air nozzle is threadedly connected to the threaded seat.

[0011] Preferably, the straight pipe section has a Venturi channel.

[0012] Preferably, the axial length of the contraction section of the Venturi channel is shorter than the axial length of the diffusion section.

[0013] Preferably, the straight pipe section is sealed and inserted into the feed pipe, and the outlet of the straight pipe section is a beveled opening that extends to the outlet of the feed pipe, with the bevel of the bevel facing the tangential inner side of the cyclone separator.

[0014] The present invention achieves the following technical effects compared to the prior art: In the flux recovery system of the present invention, the gas jet device can provide negative pressure to the solder recovery pipe as power to draw excess solder from the weld into the cyclone separator for purification. The purified solder falls into the solder bin under the action of gravity settling, and can then be supplied to the solder gun for reuse, thereby reducing material loss and avoiding solder waste.

[0015] The other technical solutions of this invention achieve the following technical effects compared to the prior art: 1. In the flux recovery system of the present invention, the flux recovery pipe includes a recovery hose and a recovery rigid pipe. The cross-section of the suction section of the recovery rigid pipe is rectangular, which can adapt to the narrow and long internal space and structural constraints of the narrow gap bevel, and solves the problem of penetrating into narrow spaces. The cross-section of the transition section of the recovery rigid pipe gradually transitions from rectangular to circular, achieving a smooth transition of the cross-sectional shape. This can gradually expand the flow area to reduce airflow resistance, increase the conveying speed, reduce airflow disturbance, and ensure that the flux remains unobstructed during the conveying process.

[0016] 2. In the flux recovery system of the present invention, a filter plate is provided at the inlet of the recovery rigid pipe, forming the first mechanical filtration barrier. Its main function is to perform preliminary screening of the recovered flux, blocking larger particles of slag shell, oxide blocks, and other impurities from entering the recovery system, thereby preventing pipe blockage. This structure balances airflow permeability and screening effect, ensuring that the particle size of the drawn-in flux basically meets the requirements of subsequent cyclone separation, thus improving the reliability of the overall recovery system and the quality of flux reuse.

[0017] 3. In the flux recovery system of the present invention, the gas jet includes a straight pipe section and an inclined pipe section with an obtuse angle. At the moment the solder is drawn back, a specific velocity field and separation zone are formed. The significant differences in diameter, mass, density and aerodynamic characteristics of different solders after welding allow the lighter qualified flux to be smoothly drawn into the straight pipe section, while the heavier and more inertial special-sized metal solders fall back from the inclined pipe section under the action of centrifugal force or gravity, and are effectively separated and discharged. This achieves the pre-separation of solder and is an indispensable key component for ensuring high-end welding quality and improving material utilization.

[0018] 4. In the flux recovery system of the present invention, the filter plate constitutes the first filtration barrier, the gas jet device constitutes the second filtration barrier, and the cyclone separator constitutes the third filtration barrier. The flux, after being purified through three stages of mechanical isolation, inertial separation, and centrifugal separation, has a cleanliness and particle size that fully meets the reuse requirements of narrow gap submerged arc welding and can be returned to the welding system for use directly or after simple treatment. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained by analyzing these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the flux recovery system (when installed in the solder bin) in an embodiment of the present invention; Figure 2 This is a schematic diagram of the flux recovery system in an embodiment of the present invention; Figure 3 This is a three-dimensional structural diagram of the cyclone separator in an embodiment of the present invention; Figure 4 This is a cross-sectional view of the cyclone separator in an embodiment of the present invention; Figure 5 This is a front view schematic diagram of the recyclable rigid pipe in an embodiment of the present invention; Figure 6 This is a side view of the recyclable rigid tube in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the inlet of the recovery rigid pipe in an embodiment of the present invention; Figure 8 This is a front view schematic diagram of the gas jet device in an embodiment of the present invention; Figure 9 This is a cross-sectional view of the gas jet generator in an embodiment of the present invention; Figure 10 This is a top view of the gas jet generator in an embodiment of the present invention.

[0021] Explanation of reference numerals in the attached figures: 1. Cyclone separator; 11. Main shell; 12. Separation pipe; 13. Separation chamber; 14. Feed pipe; 15. Dust outlet; 16. Discharge outlet; 2. Gas ejector; 21. Jet tube; 22. Air nozzle; 23. Threaded seat; 24. Jet outlet; 25. Air inlet; 26. Suction port; 27. Sealing body; 201. Straight pipe section; 202. Inclined pipe section; 203. Contraction section; 204. Diffusion section; 3. Solder recovery pipe; 31. Recycling hose; 32. Recycling rigid pipe; 33. Rigid pipe mounting bracket; 34. Partition plate; 321. Transition section; 322. Suction section; 4. Solder container; 5. Weld bevel. 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 analyzed and obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] The purpose of this invention is to provide a flux recovery system to solve the problems existing in the prior art. During the welding process, the gas jet can provide negative pressure to the flux recovery pipe to draw excess flux from the weld into the cyclone separator for purification. The purified flux falls into the flux bin under the action of gravity sedimentation, and can then be supplied to the flux gun for reuse, thereby reducing material loss and avoiding flux waste.

[0024] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0025] like Figures 1 to 10 As shown, this embodiment provides a flux recovery system for use in conjunction with the solder bin 4 of a welding system. The flux recovery system is responsible for recovering solder, while the solder bin 4 of the welding system is responsible for the storage and supply of solder.

[0026] The flux recovery system includes a cyclone separator 1, a gas jet injector 2, and a flux recovery pipe 3 (refer to recovery rigid pipe 31 and recovery flexible pipe 32). The cyclone separator 1 includes an inlet pipe 14, a dust outlet 15, and a discharge outlet 16. The discharge outlet 16 is located at the bottom of the cyclone separator 1. The discharge outlet 16 is used to connect to the flux bin 4. Specifically, the cyclone separator 1 is installed on top of the flux bin 4, and the top of the flux bin 4 has a discharge port that communicates with the discharge outlet 16. A screen is connected between the discharge outlet 16 of the cyclone separator 1 and the discharge port of the flux bin 4. The screen can filter particles that are too large to meet the flux usage standards. The screen can be installed either on the discharge outlet 16 or on the discharge port of the flux bin 4. The gas jet injector 2 includes an outlet 24, an air inlet 25, and a suction port 26. The outlet 24 is sealed to the feed pipe 14, the air inlet 25 is used to connect to the compressed gas supply equipment, and the suction port 26 is connected to the solder recovery pipe 3.

[0027] Working principle: The compressed gas supply equipment delivers compressed gas (dry compressed air) to the inlet 25 of the gas ejector 2, creating a negative pressure environment at the inlet 25 of the gas ejector 2. This provides negative pressure suction to the solder recovery pipe 3, drawing the solder to be recovered into the solder recovery pipe 3. The compressed gas, carrying the solder, is injected into the cyclone separator 1 through the ejection outlet 24. A vortex is formed in the cyclone separator 1, and under the action of centrifugal force, the solder is driven to separate from the gas and dust. The solder falls onto the screen under gravity. The solder particles that meet the size requirements fall into the solder bin 4 by gravity and are recovered. Particles that do not meet the size requirements will continue to be separated in the cyclone separator 1 with the airflow. Finally, the unsuitable particles are opened and poured out. Dust and impurities are discharged from the dust outlet 15 of the cyclone separator 1. This allows the excess solder in the welding process to be recycled, reducing material loss and avoiding the impact of solder residue on weld quality.

[0028] In one embodiment, the cyclone separator 1 further includes a main housing 11 and a separation tube 12. (See reference...) Figure 3 and Figure 4 As shown, the top wall of the main housing 11 has an inlet, and the cross-section of the side wall of the main housing 11 is circular. The bottom wall of the main housing 11 has a discharge port 16. The inlet of the separation pipe 12 extends into the main housing 11 through the inlet, and the separation pipe 12 is sealed and fixedly connected to the inlet. An annular separation chamber 13 is formed between the separation pipe 12 and the main housing 11, and the inlet of the separation pipe 12 is close to the discharge port 16. A screen is installed on the discharge port 16. The outlet of the separation pipe 12 is located above the main housing 11, and the outlet of the separation pipe 12 constitutes a dust discharge port 15. The feed pipe 14 communicates with the separation chamber 13, and the axis of the feed pipe 14 is tangent to the cross-section of the side wall of the main housing 11.

[0029] The main function of the feed pipe 14 is to guide the flux and airflow mixture delivered by the gas jet injector 2 into the separation chamber 13. The separation chamber 13 is the key area for separating flux and impurities. It utilizes the rotating vortex formed by the tangential entry of high-speed airflow to cause flux particles to move towards the wall under centrifugal force. Narrow-gap submerged arc welding flux has a high density and uneven particle size. This design ensures that the coarser qualified flux falls along the wall under gravity, while the lighter dust and fine impurities are carried by the airflow into the separation pipe 12 and then discharged from the outlet (dust discharge port 15) of the separation pipe 12, achieving efficient separation.

[0030] In one embodiment, the main housing 11 serves as the supporting and sealing body of the cyclone separator 1, with all other components mounted on the main housing 11 to form a closed separation space. Its structure must possess sufficient rigidity and airtightness to withstand the internal positive pressure from the jet airflow and ensure that the separation process is not disturbed by external airflow. To address the metal debris and dust that may be present during flux recovery, the inner wall of the main housing 11 should be smooth and wear-resistant to reduce adhesion and abrasion.

[0031] In one embodiment, the feed pipe 14 is connected to the outlet 24 of the gas ejector 2 and is secured with clamps to ensure a firm connection and easy disassembly. Given the characteristics of narrow-gap submerged arc welding flux particles being fine and prone to containing small impurities, the feed pipe 14 is designed to ensure a smooth airflow, prevent flux accumulation at the inlet, and guarantee continuous and uniform feeding, providing stable conditions for subsequent centrifugal separation.

[0032] In one embodiment, the separation pipe 12 is located in the center of the main housing 11, and its inlet is provided with a bent baffle and a certain height is reserved. This structure can effectively prevent qualified flux from being carried into the dust discharge port 15 by the airflow. In narrow-gap submerged arc welding flux recovery, the height of the separation pipe 12 and the angle of the baffle are specially designed to adjust the airflow rising speed, ensuring that only low-density, small-particle-size dust and impurities are sucked into the dust discharge port 15, thereby ensuring that the particle size and cleanliness of the recovered flux meet the process requirements of narrow-gap welding.

[0033] In one embodiment, in narrow-gap submerged arc welding, the flux is prone to generating fine dust and oxide slag after repeated use. The dust discharge port 15 is connected to an external recycling bag or centralized filtration system, which can effectively collect these wastes, prevent dust from escaping, maintain a clean working environment, and avoid fine impurities from mixing into the recycled flux and affecting the quality of subsequent welding.

[0034] In one embodiment, the main housing 11, the separation pipe 12, and the feed pipe 14 are connected by welding to ensure sealing and structural strength.

[0035] In one embodiment, the solder recovery pipe 3 includes a recovery hose 31 and a recovery rigid pipe 32. (See reference...) Figures 5 to 7 As shown, the outlet of the recovery hose 31 is connected to the suction port 26 of the gas ejector 2. The inlet of the recovery hose 31 is connected to the outlet of the recovery rigid tube 32. The recovery rigid tube 32 is fixedly connected to the solder bin 4 via a rigid tube mounting bracket 33. The inlet of the recovery rigid tube 32 is positioned downwards and close to the flux recovery area. The recovery rigid tube 32 is used for recovery close to the weld area. The recovery rigid tube 32, in conjunction with the rigid tube mounting bracket 33, is fixedly connected to the solder bin 4, which can reduce the overall shaking of the solder recovery tube 3. The recovery rigid tube 32 can be made of steel. The recovery hose 31 can be made of plastic.

[0036] In one embodiment, the recovery rigid tube 32 includes a transition section 321 and a suction section 322. The suction section 322 has a rectangular cross-section, and the wider side of the rectangle is smaller than the narrow gap weld. Typically, the narrow gap weld is 14mm to 18mm, so the wider side of the rectangle only needs to be less than 14mm. This allows the suction section 322 to form a long and narrow flat-headed tube, adapting to the narrow and confined internal space of the narrow gap weld bevel 5 (i.e., weld). This allows it to extend into the weld bevel 5 (i.e., weld) for precise recovery close to the weld area. The rectangular cross-sectional shape helps maintain a large adsorption coverage area within a limited space, improving recovery efficiency. The transition section 321 is connected to the recovery hose 31. As a transition section for airflow and flux transport in the recovery system, the transition section 321 adopts a variable cross-section design. Specifically, the cross-section of the transition section 321 gradually transitions from rectangular to circular from one end near the suction section 322 to the other, achieving a smooth transition in cross-sectional shape. By gradually increasing the flow area, airflow resistance is reduced, transport speed is increased, and airflow disturbance is minimized, ensuring unobstructed flux transport during the process. This adapts to the strict constraints on the size and shape of the recovery tool under narrow gap conditions. The transition section 321 is connected to the recovery hose 31, which has a circular cross-section. The end of the transition section 321 near the suction section 322 has the same cross-sectional diameter as the suction section 322, and the end of the transition section 321 connected to the recovery hose 31 matches the cross-sectional dimensions of the recovery hose 31. Preferably, the circumscribed circle diameter of the rectangular cross-section of the suction section 322 is equal to or smaller than the circular cross-section of the recovery hose 31. The solder recovery pipe 3 is specifically designed to address the characteristics of small and easily suspended flux particles in narrow gap welding. It optimizes the transport stability of the gas-solid two-phase flow and prevents flux from depositing inside the pipe.

[0037] In one embodiment, the inlet of the recovery rigid pipe 32 is equipped with a filter plate, forming the first mechanical filtration barrier. Its main function is to perform preliminary screening of the recovered flux, blocking larger particles of slag shell, oxide blocks, and other impurities from entering the recovery system, thereby preventing pipe blockage. This structure balances airflow permeability and screening effect, ensuring that the particle size of the drawn-in flux basically meets the requirements of subsequent cyclone separation, improving the overall reliability of the recovery system and the quality of flux reuse.

[0038] In one embodiment, the filter plate is two parallel or staggered partition plates 34.

[0039] In one embodiment, the gas ejector 2 includes an ejector tube 21 and an air nozzle 22. The ejector tube 21 includes a straight section 201 and an inclined section 202. (See reference) Figures 8 to 10As shown, the inlet of the inclined tube section 202 is connected to the solder recovery pipe 3, and the inlet of the inclined tube section 202 constitutes the suction port 26. The outlet of the inclined tube section 202 is connected to the inlet of the straight tube section 201, and the outlet of the straight tube section 201 is coaxially connected to the feed pipe 14, and the outlet of the straight tube section 201 constitutes the injection port 24. The inlet of the air nozzle 22 is used to connect to the compressed gas supply equipment, and the inlet of the air nozzle 22 constitutes the air inlet 25. The outlet of the air nozzle 22 is connected to the inclined tube section 202, and the air nozzle 22 is coaxially arranged with the straight tube section 201, with the outlet of the air nozzle 22 extending to the inlet of the straight tube section 201. The obtuse angle between the straight pipe section 201 and the inclined pipe section 202 creates an acute angle between the suction port 26 (inclined pipe section 202) and the air nozzle 22. When high-pressure airflow is supplied to the air nozzle 22, the acute angle clamping helps create negative pressure within the inclined pipe section 202, guiding the solder towards the cyclone separator 1. The gas jet injector 2, through the coordinated design of its four main components, perfectly meets the core requirements of narrow-gap submerged arc welding solder recovery: it solves the pain points of traditional recovery methods such as "high energy consumption, incomplete recovery, high noise, and easy clogging," and maximizes the utilization of gas kinetic energy through axis alignment verification. Its compact structure and stable operation significantly reduce operating costs and noise while improving solder recovery rates, making it a highly efficient solution for narrow-gap submerged arc welding solder recovery scenarios.

[0040] In one embodiment, a threaded seat 23 is provided on the inclined tube section 202, and the air nozzle 22 is threadedly connected to the threaded seat 23. The threaded seat 23 is a key structural component that ensures the overall accuracy of the jet injector. The threaded seat 23 has positioning and centering functions: on the one hand, it fixes the installation position of the air nozzle 22, ensuring that the air outlet axis of the air nozzle 22 is precisely aligned with the air inlet axis of the straight tube section 201, avoiding high-pressure airflow turbulence and uneven distribution of negative pressure field due to axis misalignment; on the other hand, it can further correct the alignment of the overall axis of the gas jet injector 2 through the verification of the core welding rod, ensuring that the coaxiality error of each component is controlled within 0.1mm from the assembly level; the threaded seat 23 also has a structural reinforcement function: the threaded seat 23 forms a rigid connection with the inclined tube section 202 and the air nozzle 22, enhancing the stability of the overall structure of the gas jet injector 2, avoiding component displacement caused by vibration during welding operations, and ensuring long-term operational accuracy. Key advantages: ① High axis alignment accuracy ensures that high-pressure gas flows along the optimal path, increasing kinetic energy utilization to over 95% and avoiding energy waste and reduced recovery efficiency caused by airflow deviation; ② Rigid connection design improves the vibration resistance of gas jet 2, adapts to the high-frequency vibration environment of welding operations, and prevents precision drift during long-term use; ③ Precise welding positioning simplifies the assembly process and reduces the difficulty of on-site debugging. In one embodiment, the wire seat 23 is welded to a designated position on the inclined tube section 202.

[0041] In one embodiment, the straight pipe section 201 has a Venturi flow channel, with the converging section 203 of the Venturi flow channel connected to the nozzle 22 and the ejector outlet 24 connected to the diffuser section 204. The straight pipe section 201 is the core component of the gas ejector 2 for achieving efficient solder recovery. Its Venturi flow channel precisely combines the Bernoulli fluid dynamics principle to achieve a "low-consumption, high-efficiency" negative pressure suction effect.

[0042] In one embodiment, the axial length of the contraction section 203 of the Venturi channel is shorter than the axial length of the diffusion section 204.

[0043] The constriction section 203 of the Venturi channel accelerates the incoming high-pressure compressed air into a high-speed jet, creating a strong vacuum negative pressure field within the inclined tube section 202. This design can precisely target the narrow space after narrow-gap welding, and even molten residual solder and solder fumes adhering to the gap can be firmly adsorbed by the negative pressure, solving the pain points of traditional recycling methods that are difficult to reach narrow gap dead corners and are not thoroughly recycled; The diffuser section 204 of the Venturi channel: After the high-speed jet carries the solder fumes into the diffuser section 204, the space volume increases, the airflow speed slows down, and the pressure gradually rises. This not only achieves full mixing of the solder fumes with the ambient air, avoiding solder particles from splashing or clogging due to high-speed impact, but also smoothly pushes the mixed suction material to the downstream recycling system. Key advantages: ① Only a small amount of high-pressure compressed air is needed to generate a large flow rate and high stability of negative pressure airflow, saving more than 30% energy compared to traditional suction structures; ② The negative pressure field is evenly distributed and the effective distance is precise, which is suitable for the precision recovery requirements of narrow gap welding, and the welding material recovery rate is increased to more than 98%; ③ The structure is compact and fully adaptable to narrow gap working spaces, with no redundant design that occupies extra space. In one embodiment, the inclined tube section 202 is a key flow guiding component connecting the narrow-gap welding area and the downstream recovery system. Utilizing the continuous negative pressure environment created by the straight tube section 201, the inclined tube section 202 provides a directional, unobstructed transport path for the solder. Large-diameter solder particles adsorbed by the negative pressure can naturally slide down along the inclination angle of the inclined tube section 202, avoiding solder stagnation and blockage caused by gravity accumulation or vertical channel design, thus achieving pre-separation. The inclination design logic of the inclined tube section 202: The inclination angle of the inclined tube section 202 (the obtuse angle between the inclined tube section 202 and the straight tube section 201) has been verified through fluid simulation and actual working conditions. This ensures that the solder moves rapidly under negative pressure while avoiding excessive airflow velocity and solder particle impact on the tube wall causing wear due to an excessively large angle, or solder settling and accumulation due to an excessively small angle. Key advantages: ① The directional flow design completely solves the industry pain points of "difficult recovery, easy residue, and easy clogging" of narrow-gap solder, ensuring that the solder is free of residue throughout the process; ② The inner wall of the inclined tube section 202 is treated with wear-resistant and anti-sticking material to match the high-temperature characteristics of molten solder, and there are no problems of solder adhesion and scaling after long-term use; ③ It is precisely connected with the negative pressure field of the straight tube section 201, and the airflow is consistent with the direction of solder delivery, further improving the recovery efficiency and reducing energy consumption. In one embodiment, the air nozzle 22 is the core power input component of the gas ejector 2, responsible for the stable delivery and precise distribution of high-pressure air. The inlet of the air nozzle 22 is connected to the compressed gas supply equipment via a ball valve, allowing for precise adjustment of the inlet pressure and flow rate to meet the recovery requirements under different welding conditions. The outlet of the air nozzle 22 is seamlessly connected to the threaded seat 23, stably introducing high-pressure air into the contraction section 203 of the straight pipe section 201, while simultaneously supplementing the inclined pipe section 202 with an appropriate amount of auxiliary airflow, ensuring a continuous and stable power supply for the welding material within the inclined pipe section 202. Key advantages: ① The inlet ball valve is easy to adjust, allowing for stepless pressure adjustment from 0.2MPa to 0.8MPa, adapting to welding operations with different thicknesses and gap widths; ② The airflow path of the air nozzle 22 is short and bend-free, with pressure loss controlled within 5%, ensuring the kinetic energy utilization rate of the high-pressure gas; ③ High-temperature resistant and wear-resistant alloy materials can be selected, adapting to the high-temperature environment of welding operations, and extending the service life by more than 2 times compared to conventional air nozzles.

[0044] In one embodiment, a straight pipe section 201 is sealed and inserted into the feed pipe 14. The outlet (ejection outlet 24) of the straight pipe section 201 is a beveled opening. The beveled opening (ejection outlet 24) extends to the outlet of the feed pipe 14. The bevel of the beveled opening (ejection outlet 24) faces the tangential inner side of the cyclone separator 1 to guide the airflow to form a vortex in the cyclone separator 1.

[0045] In one embodiment, a sealing body 27 is provided on the straight pipe section 201, which is used to seal the insertion into the feed pipe 14. Preferably, the sealing body 27 and the feed pipe 14 can be clamped together by a clamp.

[0046] In one embodiment, the flux recovery system is applied to the workflow of flux recovery in narrow gap bevels: This flux recovery system is an integrated pneumatic recovery and separation solution. Its operation follows a clear and continuous path: welding bevel – recovery rigid pipe 32 – recovery flexible hose 31 – gas jetter 2 – cyclone separator 1 – separation of qualified flux. This ensures that the flux is efficiently recovered from the welding bevel, graded and purified, and meets reuse standards. The entire process can be summarized into three key stages: I. Directional collection and primary mechanical filtration within the bevel: During the welding operation, the operator inserts the inlet of the recovery rigid pipe 32 of the flux recovery system into the narrow gap bevel and brings the inlet of the recovery rigid pipe 32 close to the flux layer. Under the negative pressure generated by the subsequent gas jet 2, the mixture of flux and air begins to be drawn in. The mixture first passes through the two baffles 34 at the inlet of the recovery rigid pipe 32. This structure constitutes the first-stage mechanical filtration barrier of the system. This barrier can effectively intercept and block large-sized slag shells, oxide agglomerates and other non-target large particle impurities, keeping them outside the recovery system, thereby preventing pipe inlet blockage and ensuring that the initial particle size range of the sucked-in material is basically controllable.

[0047] II. Negative pressure conveying and pneumatic inertial pre-separation: After primary filtration, the gas-solid two-phase mixture undergoes a transport configuration change within the solder recovery pipe 3 (at the transition section 321 of the recovery rigid pipe 32) before being introduced into the gas ejector 2. This stage is one of the core separation processes. (1) Negative pressure generation and delivery: High-pressure compressed air is precisely introduced into the Venturi channel of the straight pipe section 201 through the nozzle 22. After being accelerated by the contraction section 203 and the diffusion section 204 in a "small-to-large" manner, a high-speed jet is formed. According to Bernoulli's principle, a stable high-intensity negative pressure field is generated in the inclined pipe section 202. This negative pressure field provides delivery power for the entire system, ensuring that the flux is continuously and stably drawn out of the narrow bevel.

[0048] (2) Pre-separation of special metal impurities: In the inclined tube section 202, the system utilizes the significant differences in mass, density, and aerodynamic characteristics of different components in the flux mixture (qualified flux particles, fine dust, and special-sized metal solders such as welding wire tips) to perform inertial pre-separation. Lighter qualified flux particles and dust are easily diverted by the airflow and enter the feed pipe 14; while special-sized metal solders with greater mass and inertia, due to their less easily changed trajectory, are separated from the mainstream under inertia, or are guided by a designed structure to specific collection points, thereby effectively removing the main metal contaminants in the early stages of the process.

[0049] III. Centrifugal Fine Separation and Finished Product Collection: The gas-solid mixture, pre-separated by the gas jet injector 2, enters the cyclone separator 1 tangentially through the feed pipe 14, and enters its separation chamber 13 at a high speed, thus entering the final fine separation stage of the process: (1) Formation of swirling flow field and centrifugal separation: The mixed flow forms a high-speed rotating downward swirling flow along the inner wall of the annular separation chamber 13. In this strong swirling flow field, the particles are subjected to a strong centrifugal force. The flux particles with high density and qualified particle size are thrown towards the inner wall of the main shell 11 due to the large centrifugal force they receive. After decelerating due to friction with the wall surface, they slide down the conical wall under their own gravity and are finally discharged from the bottom discharge port into the qualified flux collection unit.

[0050] (2) Removal of fine impurities: Fine impurities such as dust and soot with extremely low density experience less centrifugal force and fail to deviate sufficiently from the main airflow line, moving upward with the core area of ​​the inner vortex. This part of the dust-laden airflow turns back after reaching the bottom of the cyclone separator 1, forming an upward inner vortex, which is discharged through the separation pipe 12 located in the center. The bent baffle and specific height design at the bottom of the separation pipe 12 constitute the last barrier to prevent qualified flux from being carried upward by the airflow, ensuring that only clean exhaust gas and ultrafine particles can be discharged through the dust discharge port 15 at the top and enter the external filter device or recycling bag.

[0051] The flux that has undergone the above three-stage purification process (mechanical isolation, inertial separation, and centrifugal separation) has fully met the reuse requirements for narrow-gap submerged arc welding in terms of cleanliness and particle size, and can be returned to the welding system directly or after simple treatment.

[0052] System Usage and Core Value: In narrow-gap submerged arc welding environments, the application of this system demonstrates a high degree of integration and specificity: Collaborative operation: The three components (cyclone separator 1, gas jet injector 2, and solder recovery pipe 3) are connected to form a closed production line of "solder recovery pipe 3 suction → gas jet injector 2 conveying / pre-separation → cyclone separator 1 fine separation". During installation, ensure that all interfaces are securely connected and well-sealed.

[0053] Power adjustment: By adjusting the ball valve at the front end of the nozzle 22 on the gas ejector 2, the flow rate and pressure of high-pressure air can be controlled, thereby flexibly adjusting the negative pressure suction force of the system to adapt to narrow gap bevels of different widths and depths and different flux recovery requirements.

[0054] Precisely addressing industry pain points: This system is not a simple suction system, but is specifically designed to address three major challenges in narrow-gap welding: limited space, easy contamination of flux (mixing in metal fragments), and extremely high purity requirements for recycling.

[0055] The recovery of rigid tube 32 solves the problem of reaching deep into narrow spaces.

[0056] The gas jet generator 2 not only provides power but also innovatively solves the key problem of online preliminary separation of harmful metal impurities, while achieving energy saving and low noise.

[0057] Cyclone separator 1 ensures the final purification accuracy of the flux, removes dust, and guarantees the quality of reusable welding.

[0058] Ensuring welding quality and economic benefits: The system achieves online, automatic, and efficient recovery and purification of flux, greatly reducing flux consumption and saving costs. More importantly, by thoroughly removing metallic contaminants and dust that may cause defects such as slag inclusions and porosity, it fundamentally ensures the ultra-high consistency and reliability of narrow-gap welds, which is crucial for the manufacturing of high-end equipment such as nuclear power and shipbuilding.

[0059] In summary, this flux recovery system integrates recovery, conveying, and separation functions through the precise coordination of its three main components, forming a complete closed-loop processing flow from "within the bevel" to "qualified product." It not only achieves material recycling but also serves as a key auxiliary system for ensuring the core process quality of narrow-gap submerged arc welding and improving production stability.

[0060] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A flux recovery system, characterized in that, The device includes a cyclone separator, a gas jet injector, and a solder recovery pipe. The cyclone separator includes a feed pipe, a dust discharge port, and a discharge port located at the bottom. The discharge port is used to connect to a solder bin, and a screen is provided between the discharge port and the solder bin. The gas jet injector includes an ejection port, an air inlet, and a suction port. The ejection port is sealed to the feed pipe, the air inlet is used to connect to a compressed gas supply device, and the suction port is connected to the solder recovery pipe.

2. The flux recovery system according to claim 1, characterized in that, The cyclone separator further includes a main housing and a separation tube. The top wall of the main housing is provided with an inlet, the side wall of the main housing has a circular cross-section, and the bottom wall of the main housing is provided with a discharge port. The inlet of the separation tube extends into the main housing through the inlet. The separation tube is sealed and fixedly connected to the inlet, and an annular separation chamber is formed between the separation tube and the main housing. The inlet of the separation tube is close to the discharge port, and the screen is set on the discharge port. The outlet of the separation tube is located above the main housing, and the outlet of the separation tube constitutes the dust discharge port. The feed pipe communicates with the separation chamber, and the axis of the feed pipe is tangent to the cross-section of the side wall of the main housing.

3. The flux recovery system according to claim 1, characterized in that, The solder recovery pipe includes a recovery hose and a recovery rigid pipe. The outlet of the recovery hose is connected to the suction port, and the inlet of the recovery hose is connected to the outlet of the recovery rigid pipe. The recovery rigid pipe is fixedly connected to the solder bin by a rigid pipe mounting bracket, and the inlet of the recovery rigid pipe is set downward and close to the flux recovery area.

4. The flux recovery system according to claim 3, characterized in that, The recovery rigid pipe includes a suction section and a transition section arranged sequentially from the inlet to the outlet. The suction section has a rectangular cross-section. The transition section is connected to the recovery hose, and the recovery hose has a circular cross-section. The cross-section of the transition section gradually transitions from rectangular to circular from one end near the transition section to the other end.

5. The flux recovery system according to claim 3, characterized in that, The inlet of the recovery tube is equipped with a filter plate.

6. The flux recovery system according to any one of claims 1-5, characterized in that, The gas ejector includes an ejector tube and a nozzle. The ejector tube includes a straight section and an inclined section. The inlet of the inclined section is connected to the solder recovery tube, forming the suction port. The outlet of the inclined section is connected to the inlet of the straight section. The outlet of the straight section is coaxially connected to the feed tube, forming the ejector outlet. The inlet of the nozzle is used to connect to a compressed gas supply device, forming the air inlet. The outlet of the nozzle communicates with the inclined section. The nozzle is coaxially arranged with the straight section, and the outlet of the nozzle extends to the inlet of the straight section. There is an obtuse angle between the straight section and the inclined section.

7. The flux recovery system according to claim 6, characterized in that, The inclined tube section is provided with a threaded seat, and the air nozzle is threadedly connected to the threaded seat.

8. The flux recovery system according to claim 6, characterized in that, The straight pipe section has a Venturi flow channel.

9. The flux recovery system according to claim 8, characterized in that, The axial length of the contraction section of the Venturi channel is shorter than the axial length of the diffusion section.

10. The flux recovery system according to claim 6, characterized in that, The straight pipe section is sealed and inserted into the feed pipe. The outlet of the straight pipe section is a beveled opening that extends to the outlet of the feed pipe. The bevel of the beveled opening faces the tangential inner side of the cyclone separator.

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