Heat exchanger tube bundle high pressure cleaning apparatus

Abstract

This invention relates to high-pressure cleaning equipment for heat exchanger tube bundles, including a spraying mechanism and a rolling base assembly supporting the heat exchanger tube bundles. It also includes a control room and a water supply system. The control room houses a controller that connects the spraying mechanism and the rolling base assembly via signal transmission. The spraying mechanism is connected to the water supply system. A camera on the spraying mechanism transmits images to the controller, which displays the images and controls the cleaning posture of the spraying mechanism. This achieves automated and visualized control of the cleaning process, improving cleaning efficiency and quality, reducing operator workload, and ensuring operational safety.

Description

Technical Field

[0001] This invention relates to the field of cleaning equipment technology, specifically to high-pressure cleaning equipment for heat exchanger tube bundles. Background Technology

[0002] As a core piece of equipment in the field of industrial heat transfer, heat exchangers use their tube bundle walls as the main heat transfer surface. During long-term operation, these surfaces are prone to the accumulation of fouling materials such as carbonate and sulfate scale, biological slime, rust, and particulate matter. This fouling can create a vicious cycle of "fouling-increased thermal resistance-reduced flow rate," leading to a significant decrease in heat transfer efficiency. Experiments show that when the thermal resistance of the fouling increases by 30%, the heat transfer efficiency can decrease by 15-20%. At the same time, it can also increase fluid resistance and energy consumption. In severe cases, it can even cause safety hazards such as local overheating of the tube bundle and corrosion perforation, affecting the normal operation of the equipment and the continuity of production.

[0003] Currently, there are two main methods for cleaning heat exchanger tube bundles: one is manual cleaning, where operators use handheld high-pressure water guns to rinse the tube bundles. This method is labor-intensive, has low cleaning efficiency, and poses safety hazards due to high-pressure water spraying. The other is semi-automatic cleaning equipment, which automates the cleaning of heat exchanger tube bundles through remote control or programming. However, the degree of automation is limited, and there are problems such as cumbersome operating procedures and a high degree of reliance on manual labor. Summary of the Invention

[0004] To address the shortcomings of the existing technology, this invention proposes a high-pressure cleaning device for heat exchanger tube bundles, which enables automated and visualized control of the cleaning process, improves cleaning efficiency and quality, reduces the labor intensity of operators, and ensures operational safety.

[0005] The high-pressure cleaning equipment for heat exchanger tube bundles includes a spraying mechanism and a rolling base assembly supporting the heat exchanger tube bundles. It also includes a control room and a water supply system. The control room is equipped with a controller that connects the spraying mechanism and the rolling base assembly. The spraying mechanism is connected to the water supply system. The spraying mechanism is equipped with a camera that transmits images to the controller. The controller displays the images and controls the cleaning posture of the spraying mechanism.

[0006] Furthermore, the spraying mechanism includes a movable support and a spraying robot arm mounted on the movable support. A cleaning spray gun is connected to the front end of the spraying robot arm, and a camera is located at the front end of the spraying robot arm.

[0007] Furthermore, the mobile support includes a ground rail, a lifting support slidably mounted on the ground rail, and a lifting slider slidably mounted on the lifting support. The lifting slider is equipped with a telescopic frame that can slide laterally and is perpendicular to the ground rail on a horizontal plane. The spraying robot is located at the end of the telescopic frame.

[0008] Furthermore, the lifting support is equipped with a support translation motor that drives the lifting support to move horizontally along the ground rail, the lifting slider is equipped with a slider lifting motor that drives the lifting slider to move up and down along the lifting support, and the lifting slider is also equipped with a telescopic drive motor that drives the telescopic frame to slide laterally.

[0009] Furthermore, the rolling base assembly includes a roller support and a pair of support rollers rotatably mounted on the roller support. The pair of support rollers are spaced apart on the roller support, and the roller support is also equipped with a rotary motor for driving the support rollers to rotate.

[0010] Furthermore, the water supply system includes a booster pump, a water storage tank, a secondary water tank, and a heater. The heater is located in the secondary water tank, the booster pump is connected between the water storage tank and the secondary water tank, and the secondary water tank is connected to the spraying mechanism.

[0011] Furthermore, the controller integrates an image recognition system and a PLC control system. The camera captures real-time images of the heat exchanger tube bundle and transmits them to the controller. The image recognition system preprocesses and extracts features from the images to accurately identify the location, thickness, and type of stains on the images, and converts the recognition results into electrical signals that are transmitted to the PLC control system.

[0012] Furthermore, the PLC control system automatically adjusts the cleaning posture of the spraying mechanism, the spray pressure of the cleaning spray gun, and the rotation speed of the rolling base assembly based on the electrical signals transmitted by the image recognition system.

[0013] Compared with existing technologies, the beneficial effects of this invention are as follows: real-time images of the tube bundle are captured by a camera, and the location, thickness, and type of stains are accurately identified by an image recognition system. The PLC control system automatically adjusts the cleaning parameters based on the identification results, avoiding blind rinsing, improving cleaning quality, and saving water and energy. The entire cleaning process is automatically controlled by the controller, eliminating the need for operators to manually operate the high-pressure water gun and adjust the equipment position. Operators only need to monitor the cleaning process in the control room, which significantly reduces labor intensity and avoids the safety hazards caused by high-pressure water jets, thus improving operational safety. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art 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 based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the structure of the present invention.

[0016] Figure 2This is a schematic diagram of the spray washing mechanism in this invention.

[0017] Figure 3 This is a system structure diagram of the controller in this invention.

[0018] Among them: spray washing mechanism 1, mobile support 11, spray washing robot 12, cleaning spray gun 121, camera 122, ground rail 111, lifting support 112, lifting slider 113, telescopic frame 114, support translation motor 115, slider lifting motor 116, telescopic drive motor 117. Rolling base assembly 2, roller bracket 21, support roller 22, rotary motor 23; Control room 3, controller 31, image recognition system 311, PLC control system 312; Water supply system 4, booster pump 41, water storage tank 42, auxiliary water tank 43, heater 44. Detailed Implementation

[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0020] A high-pressure cleaning device for heat exchanger tube bundles includes a spraying mechanism 1, a rolling base assembly 2, a control chamber 3, and a water supply system 4. The control chamber 3 is equipped with a controller 31 that controls the spraying mechanism 1, the rolling base assembly 2, and the water supply system 4. All components work together to achieve efficient and precise cleaning of the heat exchanger tube bundles.

[0021] The rolling base assembly 2 supports the heat exchanger tube bundle and includes a roller support 21 and a pair of support rollers 22 rotatably mounted on the roller support 21. The pair of support rollers 22 are parallel and spaced apart on the roller support 21. The surfaces of the support rollers 22 are fitted with anti-slip rubber sleeves to prevent the heat exchanger tube bundle from sliding during support and to reduce wear on the tube bundle surface. A rotary motor 23 is fixedly mounted on the roller support 21. The output shaft of the rotary motor 23 is connected to one of the support rollers 22 via a coupling. The two support rollers 22 are connected by a chain drive. When the rotary motor 23 operates, it drives the two support rollers 22 to rotate synchronously, thereby rotating the heat exchanger tube bundle placed on the support rollers 22, achieving comprehensive circumferential cleaning of the tube bundle. The rotary motor 23 is a stepper motor, allowing for stepless speed adjustment within a range of 0-10 r / min to adapt to different cleaning requirements.

[0022] The spray cleaning mechanism 1 is used to perform high-pressure spray cleaning on the heat exchanger tube bundle. It includes a movable support 11 and a spray cleaning robot 12. The spray cleaning robot 12 is a four-axis articulated robot that can flexibly adjust the cleaning posture. The front end of the spray cleaning robot 12 is connected to a cleaning spray gun 121. The cleaning spray gun 121 is a high-pressure atomizing spray gun, which can realize atomized spraying, improve the cleaning effect, and reduce water waste. The front end of the spray cleaning robot 12 is also fixedly equipped with a camera 122. The camera 122 is a high-definition industrial camera. The lens is parallel to the spray direction of the cleaning spray gun 121 and moves synchronously with the cleaning spray gun 121 to collect images of the surface of the heat exchanger tube bundle in real time and transmit the image signal to the controller 31.

[0023] The movable support 11 includes a ground rail 111, a lifting support 112, a lifting slider 113, and a telescopic frame 114. The ground rail 111 is fixedly installed on the ground and is arranged along the length of the heat exchanger tube bundle. The lifting support 112 is slidably mounted on the ground rail 111, and a support translation motor 115 is fixedly installed on the lifting support 112. The output shaft of the support translation motor 115 is connected to a gear, and the ground rail 111 is provided with a rack that meshes with the gear. When the support translation motor 115 is working, it drives the lifting support 112 to translate along the ground rail 111 through the meshing transmission of the gear and rack, thereby realizing the movement of the spraying mechanism 1 along the length of the tube bundle. Specifically, the stroke of the lifting support 112 on the ground rail 111 is greater than the length of the heat exchanger tube bundle, which facilitates the spraying and cleaning of the end faces of the heat exchanger tube bundle.

[0024] The lifting slider 113 is slidably mounted on the lifting bracket 112 via a slide rail. A slider lifting motor 116 is fixedly installed on the lifting slider 113, which drives the lifting slider 113 to rise and fall along the lifting bracket 112, thereby realizing the height adjustment of the spray washing robot 12.

[0025] The telescopic frame 114 is slidably mounted on the lifting slider 113 via a slide rail. The sliding direction of the telescopic frame 114 is perpendicular to the ground rail 111 on the horizontal plane. A telescopic drive motor 117 is fixedly installed on the lifting slider 113, which drives the telescopic frame 114 to slide laterally, thereby adjusting the distance between the spraying robot 12 and the heat exchanger tube bundle. The support translation motor 115, the slider lifting motor 116, and the telescopic drive motor 117 are all servo motors, which have high control precision. They also employ a gear and rack transmission mechanism to adjust the positions of the lifting support 112, the lifting slider 113, and the telescopic frame 114, enabling precise positioning.

[0026] The water supply system 4 provides high-pressure hot water to the spraying mechanism 1, including a booster pump 41, a water storage tank 42, an auxiliary water tank 43, and a heater 44. The water storage tank 42 is used to store cleaning water and has an inlet and a drain for easy water replenishment and drainage. The inlet of the booster pump 41 is connected to the water storage tank 42 through a pipe, and the outlet is connected to the auxiliary water tank 43 through a pipe. The booster pump 41 is a high-pressure plunger pump that can boost the water pressure to 10-50MPa to meet the cleaning needs of different stains. The heater 44 is fixedly installed inside the auxiliary water tank 43 and uses an electric heating tube with adjustable power. It can heat the water in the auxiliary water tank 43 to 30-80℃, improving the dissolution and cleaning effect on stubborn stains. The auxiliary water tank 43 is connected to the cleaning spray gun 121 through a high-pressure hose to provide high-pressure hot water to the cleaning spray gun 121. The auxiliary water tank 43 is equipped with a temperature sensor and a pressure sensor to detect the water temperature and pressure in real time and transmit the detection signals to the controller 31.

[0027] The control room 3 is equipped with a controller 31, which is an industrial-grade PLC controller 31. The controller 31 is equipped with a display screen, which can display the images transmitted by the camera 122, the working parameters of the water supply system 4 (water temperature, water pressure), the position parameters of the spraying mechanism 1, and the rotation parameters of the rolling base assembly 2 in real time. At the same time, control commands can be manually input to realize manual control.

[0028] The controller 31 integrates an image recognition system 311 and a PLC control system 312. The real-time image of the heat exchanger tube bundle captured by the camera 122 is transmitted to the image recognition system 311. The image recognition system 311 preprocesses the image and extracts features. Through deep learning algorithms, it accurately identifies the location, thickness, and type of stains (such as scale, oil, rust, etc.) on the image. The image recognition system 311 converts the recognition result into an electrical signal and transmits it to the PLC control system 312. Based on the electrical signal and combined with the preset control logic, the PLC control system 312 automatically adjusts the working status of the spray washing mechanism 1, the rolling base assembly 2, and the water supply system 4.

[0029] The working principle of this invention is as follows: Heater 44 starts to heat the water in auxiliary water tank 43. When the water temperature reaches the preset value (set according to the type of stain; 60-80℃ for scale stains and 40-60℃ for oil stains), and when image recognition system 311 detects stains on the surface of heat exchanger tube bundle, PLC control system 312 controls booster pump 41 to start, pressurizing the water in storage tank 42 and delivering it to auxiliary water tank 43 to pump out the hot water in auxiliary water tank 43. It also controls the spray cleaning robot 12 to adjust to the corresponding cleaning posture, and the bracket translation motor 115 and slider lifting... The lowering motor 116 and the telescopic drive motor 117 work together to move the cleaning spray gun 121 to the location of the stain. At the same time, the rotary motor 23 is started to drive the heat exchanger tube bundle to rotate, achieving comprehensive cleaning of the stain. During the cleaning process, the image recognition system 311 monitors the stain removal in real time. When it is recognized that the stain has been removed, the PLC control system 312 automatically reduces the water supply pressure and increases the tube bundle rotation speed to move to the next area for cleaning. When the entire tube bundle is cleaned, the PLC control system 312 controls each component to stop in sequence, completing the cleaning operation.

[0030] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A high-pressure cleaning device for heat exchanger tube bundles, comprising a spraying mechanism and a rolling base assembly supporting the heat exchanger tube bundles, characterized in that, It also includes a control room and a water supply system. The control room is equipped with a controller that connects the spray washing mechanism and the rolling base assembly. The spray washing mechanism is connected to the water supply system. The spray washing mechanism is equipped with a camera that transmits images to the controller. The controller displays the images and controls the cleaning posture of the spray washing mechanism.

2. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 1, characterized in that, The spraying mechanism includes a movable support and a spraying robot arm mounted on the movable support. A cleaning spray gun is connected to the front end of the spraying robot arm, and a camera is located at the front end of the spraying robot arm.

3. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 2, characterized in that, The mobile support includes a ground rail, a lifting support that is slidably mounted on the ground rail, and a lifting slider that is slidably mounted on the lifting support. The lifting slider is equipped with a telescopic frame that can slide laterally and is perpendicular to the ground rail on the horizontal plane. The spraying robot is located at the end of the telescopic frame.

4. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 3, characterized in that, The lifting support is equipped with a support translation motor that drives the lifting support to move horizontally along the ground rail, the lifting slider is equipped with a slider lifting motor that drives the lifting slider to move up and down along the lifting support, and the lifting slider is also equipped with a telescopic drive motor that drives the telescopic frame to slide laterally.

5. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 1, characterized in that, The rolling base assembly includes a roller support and a pair of support rollers rotatably mounted on the roller support. The pair of support rollers are spaced apart on the roller support, and the roller support is also equipped with a rotary motor for driving the support rollers to rotate.

6. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 1, characterized in that, The water supply system includes a booster pump, a water storage tank, a secondary water tank, and a heater. The heater is located in the secondary water tank. The booster pump is connected between the water storage tank and the secondary water tank. The secondary water tank is connected to the spraying mechanism.

7. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 1, characterized in that, The controller integrates an image recognition system and a PLC control system. The camera captures real-time images of the heat exchanger tube bundle and transmits them to the controller. The image recognition system preprocesses and extracts features from the images to accurately identify the location, thickness, and type of stains on the images, and converts the recognition results into electrical signals that are transmitted to the PLC control system.

8. The high-pressure cleaning equipment for heat exchanger tube bundles according to claim 7, characterized in that, The PLC control system automatically adjusts the cleaning posture of the spraying mechanism, the spray pressure of the cleaning spray gun, and the rotation speed of the rolling base assembly based on the electrical signals transmitted by the image recognition system.

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