A microwave ultraviolet curing machine for trenchless repair of pipelines

Abstract

This invention discloses a microwave-UV curing machine for trenchless pipeline repair, relating to the field of trenchless pipeline repair technology. It includes a moving wheel assembly and a curing machine body that can rotate coaxially with the moving wheel assembly. A microwave mechanism and a microwave gain mechanism are arranged in the middle of the curing machine body, and a UV curing lamp is arranged at the front of the curing machine body. This invention improves pipeline repair efficiency by integrating UV and microwave modules to synergistically cure resin linings, and can be used for thick-walled pipeline repair.

Description

Technical Field

[0001] This invention relates to the field of trenchless pipeline repair technology, specifically to a microwave ultraviolet curing machine for trenchless pipeline repair. Background Technology

[0002] Roads often have many pipes laid underneath, such as sewage pipes or water pipes. If a pipe breaks, the ground needs to be excavated, which causes extensive damage, long-term congestion of pedestrians and vehicles, and consumes a lot of manpower and resources. Therefore, trenchless methods are more time-saving and manpower-saving. Trenchless methods do not require digging up the ground. After detecting the location of the pipe rupture or finding the pipe port, resin material is delivered to the rupture location (the diameter of the resin material is generally universal) and then spread out. With the help of curing equipment, the resin is molded and cured to repair the pipe.

[0003] Currently, trenchless pipeline repair curing equipment relies solely on ultraviolet (UV) light technology, resulting in low curing efficiency. For example, a UV curing lamp for trenchless pipeline repair disclosed in patent publication CN118654190B includes multiple curing lamp units connected by flexible connectors. Each curing lamp unit includes an outer cylinder and end plates fixed to both ends of the outer cylinder. Several support plates are evenly distributed between the two end plates, arranged radially along the outer cylinder and capable of synchronously moving radially. A support frame is symmetrically fixed to the outer end face of each support plate, and a pulley system is rotatably installed on the support frame extending to the outside of the end plate. A UV lamp is arranged on each support plate between the two support frames. The curing lamp proposed in this invention is not only suitable for pipelines of different diameters, but also ensures that the distance between the UV lamp and the inner wall of the pipeline remains the same, guaranteeing that the UV lamp is always within an effective distance from the inner wall of the pipeline, thereby ensuring the curing effect of the flexible tube.

[0004] The curing process in this solution relies solely on UV light to cure the material, resulting in low curing efficiency. This is especially true for thick-walled pipes, where the penetration depth of UV light is limited, making it difficult to cure deep resin layers.

[0005] For example, the patent publication number CN119878982B discloses a method for trenchless pipeline repair using UV curing combined with a robot, which includes the following steps: S1: Using a detection robot to enter the pipeline and collect point cloud, high-definition images, and thermal imaging data; S2: Constructing a three-dimensional mesh model to fully restore the internal geometry and defect distribution of the pipeline, and marking the defect areas in the model; S3: Obtaining a repair task strategy based on the defect area type and location, including the division of repair segments and UV curing parameters; S4: Inputting the repair task strategy into the three-dimensional mesh model for virtual repair simulation, and obtaining the final repair scheme after optimizing the parameters; S5: Based on the final repair scheme, performing repair using a repair robot, and detecting the repair status in real time through a camera. This invention effectively improves the accuracy and efficiency of trenchless pipeline repair. The operation methods and steps in this solution are all aimed at collecting high-definition images and thermal imaging data for virtual simulation and robot-based repair. This solution only uses ultraviolet light curing and cannot solve the problem of low repair efficiency for thick-walled pipes.

[0006] Therefore, in response to the above problems, the applicant needs to design a microwave ultraviolet curing machine for trenchless pipeline repair to solve the problem. Summary of the Invention

[0007] The purpose of this invention is to provide a microwave ultraviolet curing machine for trenchless pipeline repair, in order to solve the problems mentioned in the background art, such as low efficiency, difficulty in curing thick-walled pipelines, and unevenness, that rely solely on light curing.

[0008] To achieve the above objectives, the present invention provides the following technical solution: A microwave ultraviolet curing machine for trenchless pipeline repair includes a moving wheel assembly and a curing machine body that can rotate coaxially with the moving wheel assembly. A microwave mechanism and a microwave gain mechanism are provided in the middle part of the curing machine body, and an ultraviolet curing lamp is provided at the front end of the curing machine body.

[0009] Furthermore, the microwave mechanism includes a microwave gain mechanism, a microwave generator, and a waveguide, with the waveguide connected to the microwave generator.

[0010] Furthermore, the microwave gain mechanism includes multiple gain horns distributed in a ring array, the cross-section of the gain horns being fan-shaped, and the multiple gain horns being installed at the outlet of the waveguide.

[0011] Furthermore, the gain speaker is positioned between the first metal shielding plate and the second metal shielding plate of the curing machine body, and the first metal shielding plate and the second metal shielding plate have the same diameter.

[0012] Furthermore, the first movable wheel assembly is connected to the motor, and the second gear is connected to the motor. The second gear meshes with the first gear, and the first gear is rotatably connected inside the first movable wheel assembly. The first movable wheel assembly also houses the curing machine body, and the curing machine body is fixedly connected to the first gear.

[0013] Furthermore, a motor and a hydraulic cylinder can be placed on the outer shell of the first movable wheel assembly. The push shaft of the hydraulic cylinder is fixed to the bottom of the push ring by a U-shaped clamp, and the push ring is hinged to the wheel support leg of the first movable wheel assembly by a hinge.

[0014] The UV curing unit emits specific wavelengths of UV light, which rapidly initiates a photoinitiator reaction on the resin surface, achieving rapid cross-linking and curing of the resin surface. The microwave curing unit generates microwaves that penetrate the resin material, causing high-frequency vibrations in the resin molecules and achieving volumetric heating from the inside out, effectively solving the problem of difficult thermal curing of deep resin layers in thick-walled pipe repair. When both work together, the UV light first completes surface shaping, forming a protective layer and fixing the shape; simultaneously, the microwaves penetrate deep into the interior for uniform heating, promoting the overall curing reaction of the resin. This synergistic mode of "rapid surface shaping" and "deep internal heating" not only significantly shortens the overall curing time but also achieves uniform and efficient curing across the entire thickness from the pipe wall to the interior of the resin, making it particularly suitable for trenchless repair projects of large-diameter, thick-walled pipes.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention utilizes a complementary mechanism of microwave heating and ultraviolet surface curing. Ultraviolet light rapidly cures the pipe surface, while microwaves rapidly and uniformly heat the deep resin. The combination of microwave curing and light curing significantly improves curing efficiency. The entire curing mechanism can rotate to achieve uniform energy distribution around the pipe, and the rotating microwave field reduces the standing wave effect, thereby improving energy utilization.

[0016] 2. This invention adopts a composite structure design that integrates ultraviolet and microwave modules in separate sections to avoid interference between them. The ultraviolet curing unit and the microwave curing unit are arranged in separate sections in the structure to avoid electromagnetic interference and photothermal coupling failure problems, and to ensure that the two curing methods operate stably and efficiently.

[0017] 3. This invention achieves directional and efficient microwave radiation through a microwave gain mechanism, which, in conjunction with a rotating mechanism, enables circumferential uniform curing, reduces microwave leakage and electromagnetic interference, and improves the electromagnetic compatibility and construction safety of the equipment.

[0018] 4. This invention uses two metal shielding plates to provide excellent reflection and absorption of microwaves, which can effectively attenuate the intensity of leaked electromagnetic waves and avoid electromagnetic interference from microwaves to the UV curing unit and control system.

[0019] 5. This invention uses an infrared temperature sensor to sense temperature changes at different curing stages and dynamically adjusts the microwave power output. For example, a PID control algorithm is used to dynamically adjust the microwave power. When the detected temperature reaches 100 ℃, the microwave controller of the device is triggered to output 200 W less; when the detected temperature reaches 110 ℃, the output is reduced by 200 W; when the detected temperature reaches 130 ℃, the output stops; making the curing process more stable and controllable. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the overall three-dimensional structure of the present invention. Figure 2 ; Figure 3 This is a three-dimensional structural diagram of the driving ring of the present invention; Figure 4 This is a three-dimensional structural diagram of the microwave mechanism of the present invention; Figure 5 This is a three-dimensional structural schematic diagram of the gain speaker of the present invention; Figure 6 This is a three-dimensional structural diagram of the internal structure of the gain speaker of the present invention; Figure 7 This is a three-dimensional structural diagram of the hinge component of the present invention.

[0021] In the diagram: 1. Curing machine body; 2. Moving wheel assembly one; 201. Opening groove; 202. Limiting groove; 3. Gear one; 4. Gear two; 5. Motor; 6. Metal shielding plate one; 7. Gain speaker; 701. Waveguide; 702. Microwave generator; 8. Metal shielding plate two; 10. Infrared temperature sensor; 11. Moving wheel assembly two; 12. Ultraviolet curing lamp; 13. Hydraulic cylinder; 14. Push ring; 15. Hinge. Detailed Implementation

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

[0023] Example 1: like Figure 1 As shown, a microwave ultraviolet curing machine for trenchless pipeline repair according to the present invention includes a moving wheel assembly 2 and a curing machine body 1 that can rotate coaxially with the moving wheel assembly 2. The middle part of the curing machine body 1 is provided with a microwave mechanism and a microwave gain mechanism, and the curing machine body 1 is provided with an ultraviolet curing lamp 12.

[0024] like Figure 2 As shown, the microwave mechanism includes a microwave gain mechanism, a waveguide 701, a microwave generator 702, and an infrared temperature sensor 10. The power supply of the microwave generator 702 is connected to an external power control device, and the signal transmission line of the infrared temperature sensor 10 is connected to an external controller such as a PLC.

[0025] The microwave gain mechanism includes multiple gain horns 7 arranged in a ring array. The cross-section of the gain horn 7 is fan-shaped. The bottom of each gain horn 7 is installed at the outlet of the waveguide 701. The waveguide 701 is connected to the microwave generator 702. Each gain horn 7 is connected to a waveguide 701 and a microwave generator 702, which is used to smoothly transition the microwave mode transmitted in the waveguide into a free space radiation wave, significantly reducing the reflection loss at the waveguide port.

[0026] The gain speaker 7, waveguide 701, and microwave generator 702 are positioned between the metal shielding plate 6 and the metal shielding plate 8 of the curing machine body 1. The metal shielding plate 6 and the metal shielding plate 8 have the same diameter and are made of highly conductive materials, such as stainless steel, aluminum alloy, or copper-based materials. Highly conductive materials have good reflection and absorption capabilities for microwaves, which can effectively attenuate the intensity of leaked electromagnetic waves and avoid electromagnetic interference from microwaves to the UV curing unit and control system; improve microwave energy utilization and reduce energy consumption; and reduce ineffective leakage by limiting the reflection and utilization of microwave energy in the curing area.

[0027] The moving wheel assembly 2 is connected to the motor 5, and a gear 4 is connected to it. The gear 4 meshes with the gear 3. The gear 3 is rotatably connected inside the moving wheel assembly 2. The moving wheel assembly 2 includes a cylindrical frame, several legs evenly distributed on the outside of the cylindrical frame, and traveling wheels set at the free ends of the legs. The curing machine body 1 is also fitted inside the moving wheel assembly 2. The curing machine body 1 is fixedly connected to the gear 3, so that the rotation of the gear 3 drives the rotation of the entire curing machine body 1. Furthermore, the problem of coil winding of the curing machine body 1 during rotation can be solved by existing technologies such as shafts or electric slip rings, ensuring that the continuous power supply is not affected by coil winding when the curing machine body 1 rotates.

[0028] The moving wheel assembly 12 has an opening slot 201 on the side near the motor 5. The opening slot 201 provides space for the meshing transmission of gear 1 3 and gear 2 4. Both moving wheel assembly 12 and moving wheel assembly 2 11 are connected to the curing machine body 1 through bearings. The moving wheel assembly 12 and moving wheel assembly 2 11 have the same diameter and the same structure. The moving wheel assembly 12 and moving wheel assembly 2 11 can directly contact the pipe. The length of the ultraviolet curing lamp 12 is one-third of the length of the entire curing machine body 1.

[0029] Example 2: This second embodiment is an optimization and improvement based on the first embodiment. Specifically, the outer shell of the first movable wheel assembly 2 can accommodate the motor 5 and the hydraulic cylinder 13. The push shaft of the hydraulic cylinder 13 is fixed to the bottom of the push ring 14 by a U-shaped clamp. The push ring 14 is hinged to the wheel support leg of the first movable wheel assembly 2 by a hinge 15. The wheel support leg is connected to the cylindrical frame by a hinge joint. The support legs of the wheels (such as casters) on the first movable wheel assembly 2 and the second movable wheel assembly 11 can rotate relative to the cylindrical frame to adapt to different pipe diameters. like Figure 3 As shown, when the hydraulic cylinder 13 is activated, a limiting groove 202 is provided on the pushing path of the hydraulic cylinder 13. The limiting groove 202 allows the U-shaped push plate on the hydraulic cylinder 13 to move back and forth, causing the push ring 14 to drive the hinge 15 to move, thereby changing the support angle of the wheel legs on the moving wheel assembly 11 and the moving wheel assembly 21 to adapt to different pipe diameters; for example Figure 7 As shown, a fixing ring can be installed at the end of the UV curing lamp 12 for connecting the traction rope to the inside of the pipe.

[0030] Example 3: This third embodiment is an optimization and improvement based on the second embodiment. Specifically, the hinge 15 on the wheel support leg of the first and second moving wheel assembly 2 is replaced with a spring. The structure is simple, no hydraulic system is required, the energy supply is reduced, and the elastic deformation of the spring is used to adapt to different pipe diameters, thus increasing the application range of the entire curing machine body 1.

[0031] The working principle of this invention is as follows: First, the main body 1 of the curing machine is pulled into the pipe to be repaired, and the ultraviolet curing lamp 12 and microwave generator 702 are turned on, so that the resin material filled in the pipe is quickly cured. The combination of microwave curing and light curing improves the curing efficiency. At the same time, the start of motor 5 drives the rotation of gear 3 and gear 4, causing the entire curing machine body 1 to rotate. The microwave mechanism and microwave gain mechanism rotate accordingly, which plays a role in uniform curing. Infrared temperature sensor 10 is used in the microwave curing zone between moving wheel assembly 21 and moving wheel assembly 12 to monitor the curing temperature of the liner in real time and adjust it in conjunction with the microwave output power to achieve precise temperature control and prevent resin overheating and degradation or insufficient curing. The gain mechanism improves the directionality and gain of microwave radiation. Through the gradually expanding structure of the horn, the microwave energy is concentrated and radiated in a predetermined direction. Metal shielding plate 6 and metal shielding plate 8 can prevent electromagnetic interference from microwaves to the UV curing unit and control system.

[0032] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A microwave ultraviolet curing machine for trenchless pipeline repair, comprising a curing machine body (1), a first moving wheel assembly (2) and a second moving wheel assembly (11) distributed on both sides of the curing machine body (1) and capable of rotating coaxially around the curing machine body (1), a microwave mechanism is provided in the middle part of the curing machine body (1), and an ultraviolet curing lamp (12) is provided at the front end of the curing machine body (1).

2. The microwave ultraviolet curing machine for trenchless pipeline repair according to claim 1, characterized in that: The microwave mechanism includes a microwave gain mechanism, a waveguide (701), a microwave generator (702), and an infrared temperature sensor (10).

3. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 2, characterized in that: The microwave gain mechanism includes several gain horns (7) distributed in a ring array. The cross-section of the gain horn (7) is fan-shaped. The gain horn (7) is installed at the outlet of the waveguide (701). The waveguide (701) is connected to the microwave generator (702).

4. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 3, characterized in that: The gain horn (7), waveguide (701) and microwave generator (702) are arranged between metal shielding plate one (6) and metal shielding plate two (8) coaxial with the curing machine body (1), and the diameters of metal shielding plate one (6) and metal shielding plate two (8) are the same.

5. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 1, characterized in that: The moving wheel assembly (2) is connected to a motor (5), and a gear (4) is connected to the motor (5). The gear (4) meshes with the gear (3). The gear (3) is rotatably connected inside the moving wheel assembly (2). The curing machine body (1) is fixedly connected to the gear (3).

6. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 5, characterized in that: The moving wheel assembly 1 (2) has an opening slot (201) on the side near the motor (5), which provides space for the meshing transmission of gear 1 (3) and gear 2 (4).

7. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 1, characterized in that: Both the first (2) and the second (11) of the moving wheel assembly are connected to the curing machine body (1) through bearings, and the first (2) and the second (11) of the moving wheel assembly have the same structure.

8. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 1, characterized in that: A hydraulic cylinder (13) can be placed on the outer shell of the first (2) of the moving wheel assembly. The push shaft of the hydraulic cylinder (13) is fixed to the bottom of the push ring (14). The push ring (14) is hinged to the wheel support leg of the first (2) of the moving wheel assembly through a hinge (15).

9. A microwave ultraviolet curing machine for trenchless pipeline repair according to claim 1, characterized in that: A fixing ring can be installed at the end of the ultraviolet curing lamp (12).

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