Ship energy-saving heat exchange device with tube bundle cleaning function

Abstract

The application provides a ship energy-saving heat exchange device with tube bundle cleaning function, and relates to the field of energy-saving heat exchange, which comprises a base, a supporting platform is installed at the top of the right side of the base, a heat exchanger is installed at the left side of the base, cleaning assemblies are installed at both ends of the heat exchanger, a power control cabinet is installed at the top of the supporting platform, and control members are arranged at the right side of the supporting platform. The heat exchange tube bundle of the heat exchanger is discretized into multiple independent heat balance unit sections along the fluid axis, and the pollution distribution matrix inside the tube bundle is constructed by combining the real-time heat exchange amount and the equivalent pollution thermal resistance of each section. The technical means can accurately locate the spatial accumulation position and evolution rate of the fouling material, overcomes the defects that the traditional technology can only judge the overall pollution condition, provides accurate data basis for subsequent on-demand cleaning, and significantly improves the pollution identification pertinence and accuracy.

Description

Technical Field

[0001] This invention relates to the field of energy-saving heat exchange technology, specifically to a ship energy-saving heat exchange device with tube bundle cleaning function. Background Technology

[0002] In modern shipbuilding, heat exchangers are a crucial component of power systems and various auxiliary systems, and their operational efficiency directly impacts a ship's energy efficiency and navigational safety. During long-term operation, impurities, salts, or microorganisms in the circulating medium can easily cause fouling deposits to form on the inner walls of the heat exchange tube bundles. This fouling significantly increases thermal resistance, leading to decreased heat exchange efficiency and increased system energy consumption.

[0003] Existing ship heat exchange systems have several limitations in addressing tube contamination. First, traditional systems typically only provide a rough assessment of overall contamination by monitoring changes in the total temperature difference or total pressure drop between the inlet and outlet. This vague assessment method cannot precisely pinpoint the specific areas where contamination occurs, making it difficult to determine the spatial distribution of contamination within the tube bundle. Second, in terms of cleaning execution mechanisms, existing technologies often employ a uniform, indiscriminate cleaning strategy. Once a performance degradation is detected, all tube bundles are cleaned with the same intensity. This not only results in unnecessary energy consumption for the cleaning components but also shortens the lifespan of mechanical parts due to excessive wear. Furthermore, ship operating conditions are highly dynamic and fluctuate due to factors such as speed, load, and sea state. Instantaneous changes in fluid temperature, pressure, and flow rate can easily lead to misjudgments in the control system, making the triggering of cleaning strategies inaccurate.

[0004] Furthermore, the flow control and cleaning actions of existing heat exchange devices are often independent, lacking deep coordination. In the early stages of fouling formation, the system cannot actively intervene in fluid distribution to inhibit further fouling expansion, resulting in poor targeting of cleaning operations. Most existing control logics are open-loop control or simple feedback control, lacking the ability to learn from historical operating conditions and a continuous optimization mechanism for control parameters, making it difficult to maintain optimal heat exchange performance and minimum operating energy consumption in the complex and ever-changing marine environment. Therefore, developing an intelligent heat exchange device with fouling thermal resistance zone identification, coordinated flow and cleaning control, and closed-loop self-learning functions is of significant practical importance for improving ship energy efficiency and equipment operational reliability. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a ship-type energy-saving heat exchange device with tube bundle cleaning function, thus solving the problems in the background technology.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: a ship energy-saving heat exchange device with tube bundle cleaning function, including a base, a support platform installed on the top right side of the base, a heat exchanger installed on the left side of the base, cleaning components installed at both ends of the heat exchanger, a power control cabinet installed on the top of the support platform, and a control component provided on the right side of the support platform;

[0007] The control component includes:

[0008] The multi-source operation data acquisition and preprocessing module is used to acquire fluid temperature, pressure, flow parameters of the heat exchanger, as well as displacement and load current data of the cleaning components in real time, and to filter the acquired data.

[0009] The pollution thermal resistance distribution identification module is used to discretize the heat exchange tube bundle of the heat exchanger into multiple calculation sections, and obtain the real-time heat transfer coefficient based on the real-time heat exchange of each section, and then calculate the equivalent pollution thermal resistance of each section to construct the pollution distribution matrix.

[0010] The flow and cleaning synergy control module is used to perform descaling operations by adjusting the flow field distribution or driving the cleaning components according to the contamination distribution matrix.

[0011] The closed-loop feedback optimization module is used to adjust the parameters of the control strategy with the goal of minimizing the total energy consumption of the system.

[0012] Preferably, the multi-source operation data acquisition and preprocessing module is connected via electrical signals to temperature sensors, pressure transmitters, electromagnetic flow meters arranged on the inlet and outlet pipelines of the heat exchanger, as well as to an encoder connected to the cleaning component, for acquiring fluid temperature, pressure, flow rate, and real-time displacement and load current of the cleaning component.

[0013] Preferably, the contamination thermal resistance distribution identification module discretizes the heat exchange tube bundle of the heat exchanger into multiple independent thermal balance unit segments along the axial flow direction of the fluid, and constructs a contamination distribution matrix inside the tube bundle by spatial mapping of the contamination thermal resistance of each segment, so as to determine the spatial accumulation state and evolution rate of the scale material.

[0014] Preferably, the flow and cleaning coordinated control module includes a flow distribution adjustment unit and a cleaning component drive unit; the flow distribution adjustment unit is used to change the flow field distribution inside the heat exchanger by adjusting the opening of the proportional valves of each branch in the early stage of pollution, so that the section with high pollution thermal resistance can obtain higher flow velocity compensation; the cleaning component drive unit is used to drive the corresponding cleaning component to start when the pollution thermal resistance exceeds a preset safety threshold, and dynamically adjust the operating frequency and reciprocating speed of the cleaning component according to the gradient change of the pollution thermal resistance.

[0015] Preferably, the closed-loop feedback optimization module constructs a comprehensive evaluation function with the goal of minimizing the total energy consumption of the system. This function includes three items: the energy consumption of pumping pressure drop due to the increase in flow rate adjustment, the compensation for the loss of heat exchange efficiency due to the increase in thermal resistance, and the mechanical operation power consumption of the cleaning components. The weight factors of each item are dynamically adjusted according to different navigation modes of the ship.

[0016] Preferably, the control unit also integrates fault self-diagnosis logic to monitor whether there is a logical conflict in the sensor feedback data, and automatically switch to a safe operation mode when a logical conflict is detected, while sending an alarm signal to the ship's central monitoring system.

[0017] Preferably, the control unit further includes a historical operating condition storage unit, used to record the thermal resistance change curves before and after each cleaning operation, and to use big data analysis to predict the next optimal cleaning time, thereby achieving predictive maintenance.

[0018] Preferably, the power control cabinet is equipped with a frequency converter driver, which is electrically connected to the output terminal of the control unit and is used to achieve stepless adjustment of the reciprocating speed of the cleaning component by changing the power supply frequency of the drive motor.

[0019] Preferably, the heat exchanger housing is provided with multiple inspection windows, and a high-temperature and high-pressure resistant transparent sight glass is installed at each window.

[0020] Preferably, a shock-absorbing pad is provided between the support platform and the base to block the physical interference of the power system vibration on the electronic components inside the control unit.

[0021] This invention provides a marine energy-saving heat exchange device with tube bundle cleaning function. It has the following beneficial effects:

[0022] 1. This invention discretizes the heat exchange tube bundle of a heat exchanger into multiple independent thermal balance unit segments along the fluid axis, and combines real-time heat exchange to invert the equivalent fouling thermal resistance of each segment to construct a fouling distribution matrix inside the tube bundle. This technique can accurately locate the spatial accumulation position and evolution rate of scale, overcoming the shortcomings of traditional techniques that can only judge the overall fouling status. It provides an accurate data basis for subsequent on-demand cleaning and significantly improves the targeting and accuracy of fouling identification.

[0023] 2. Based on the pollution distribution matrix, this invention prioritizes suppressing the spread of dirt in the early stages of pollution by adjusting the flow field distribution (such as increasing the flow velocity in the polluted section). The mechanical cleaning component is only activated when the thermal resistance of the pollution exceeds the safety threshold. The operating frequency and reciprocating speed of the cleaning component are dynamically adjusted according to the thermal resistance gradient of the pollution. This coordinated control mechanism avoids indiscriminate uniform cleaning operations, reduces unnecessary energy consumption of the cleaning component, and reduces excessive wear of mechanical parts, effectively extending the service life of the equipment.

[0024] 3. This invention constructs a comprehensive evaluation function that includes pumping pressure drop energy consumption, heat exchange efficiency loss compensation, and cleaning component power consumption through a closed-loop feedback optimization module. It dynamically adjusts each weight factor according to different ship navigation modes. The system uses the adjusted performance index feedback to automatically correct the control parameters, so that the heat exchange device always operates in the optimal energy efficiency range under varying operating conditions throughout the ship's entire life cycle. This achieves self-learning and continuous optimization of the control strategy, significantly reducing the overall energy consumption of the ship.

[0025] 4. The control unit of this invention integrates fault self-diagnosis logic, which can monitor logical conflicts in sensor data in real time and automatically switch to safe operation mode and alarm when abnormalities occur. At the same time, it records the thermal resistance change curves before and after each cleaning operation through the historical operating condition storage unit, and uses big data analysis to predict the optimal cleaning time, upgrading traditional preventive maintenance to predictive maintenance. This design effectively avoids the operational risks caused by sensor failure or misjudgment, reduces unplanned downtime, and greatly improves the operational reliability and economy of the ship's power auxiliary system. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0027] Figure 2 This is a schematic diagram of the control component of the present invention;

[0028] Figure 3 This is a schematic diagram of the power control cabinet of the present invention;

[0029] Figure 4 This is a block diagram of the control system of the present invention;

[0030] Figure 5 This is a schematic diagram of the control flow of the present invention.

[0031] The components include: 1. base; 2. heat exchanger; 3. cleaning assembly; 4. support platform; 5. power control cabinet; and 6. control components. Detailed Implementation

[0032] 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.

[0033] like Figure 1-5As shown, this embodiment of the invention provides a ship energy-saving heat exchange device with tube bundle cleaning function, including a base 1. The device is characterized in that: a support platform 4 is installed on the top right side of the base 1, a heat exchanger 2 is installed on the left side of the base 1, cleaning components 3 are installed at both ends of the heat exchanger 2, a power control cabinet 5 is installed on the top of the support platform 4, and a control component 6 is provided on the right side of the support platform 4.

[0034] The base 1 serves as the gravity support center of the entire system and is fixed to the ship's deck or equipment base via shock-absorbing pads. A support platform 4 is welded to or fixed to the top right side of the base 1 using high-strength bolts. The height of the support platform 4 is ergonomically optimized for easy maintenance by technicians. The left side of the base 1 supports the heat exchanger 2, the core container for fluid heat exchange. Cleaning components 3 are symmetrically installed at both axial ends of the heat exchanger 2. Each cleaning component 3 includes a lead screw slide arranged radially along the heat exchanger end cap, a drive motor, and flexible cleaning brushes connected to the slide block. The brush diameter is approximately equal to the inner diameter of the heat exchange tube. The cleaning component 3, through the rotation of the drive motor, drives the lead screw, causing the brush to perform axial reciprocating motion inside the heat exchange tube. The cleaning component 3 is responsible for performing online descaling on the heat exchange tube inside the heat exchanger 2 without shutting down the system. The top of the support platform 4 is equipped with a power control cabinet 5, which integrates a power distribution module, frequency converter, and surge protector to provide a stable power supply for the system. The right side of the support platform 4 is fixed with a control component 6 via a cantilever bracket. The control component 6 is the core of the intelligent operation monitoring system of the entire device. It integrates a central controller, data acquisition card, and communication gateway, and is responsible for coordinating the collaborative work of various components.

[0035] The control components include a multi-source operation data acquisition and preprocessing module, a pollution thermal resistance distribution identification module, a flow and cleanliness synergistic control module, and a closed-loop feedback optimization module.

[0036] The multi-source operation data acquisition and preprocessing module is connected to temperature sensors, pressure transmitters, and electromagnetic flowmeters arranged on the inlet and outlet pipelines of the heat exchanger via electrical signals to acquire the temperature, pressure, and flow parameters of the fluid in real time. Simultaneously, this module acquires the real-time displacement and load current of the cleaning components through encoder feedback signals. To eliminate sampling noise caused by ship engine vibration and fluid pulsation under high wind and wave conditions, this module performs a weighted moving average algorithm to filter the original sampling sequence. The preprocessed effective data is then solved using the following formula to obtain a smoothed data baseline: ;

[0037] in, The effective value of the physical quantity after filtering. For the first The original sampling data at time 10:00. These are preset time weighting coefficients, and the sum of all weighting coefficients is 1. : The sequence number of the current sampling time, which is an integer ( =0,1,2,…), the time interval corresponding to adjacent sequence numbers is a fixed sampling period. (For example =0.1 s), The offset of historical data relative to the current moment, which is an integer and ranges from [value range missing]. =0,1,…, =0,1,…, ,in =0 indicates the data at the current time. =1 indicates the data from the previous sampling period, and so on. The sliding window length parameter represents the number of historical data points included in the calculation minus 1 (i.e., the window contains...). (sampling points) The weighting coefficient corresponding to the offset jj satisfies =1, taking values ​​according to a linear decreasing pattern. Given the discrete step size of the sampling window, the control unit obtains synchronous data of temperature, pressure, and flow fields with a high signal-to-noise ratio through the calculation of this algorithm.

[0038] The pollution thermal resistance distribution identification module uses the preprocessed data to discretize the heat exchanger tube bundle along the axial flow direction of the fluid into multiple calculation segments. Each segment is considered an independent heat balance unit. First, the module calculates the first segment using the heat balance equation. Real-time heat exchange of each calculation section:

[0039] ;

[0040] In this formula, This represents the real-time heat exchange power of that section. For regional fluid mass flow rate, The specific heat capacity at constant pressure of the fluid. and The module sets the inlet and outlet temperatures for the section, respectively. Then, using the logarithmic mean temperature difference principle, it calculates the real-time heat transfer coefficient of the section under current operating conditions. By comparing the real-time heat transfer coefficient with the design heat transfer coefficient under initial cleanliness conditions, the module calculates the equivalent contamination thermal resistance for each section.

[0041] ;

[0042] in, For the first The scalar value of the pollution thermal resistance of the section, The heat transfer coefficient is obtained through real-time inversion. For the first The baseline heat transfer coefficient for the cleanliness condition of the section is initially determined through pre-delivery cleanliness testing and pre-stored in the control unit. To eliminate baseline deviations caused by equipment aging and sensor drift during long-term operation, the control unit also has a baseline calibration function: after the heat exchanger has undergone a confirmed thorough cleaning, the operator can trigger the "baseline resampling" program through the control unit's human-machine interface. The system automatically records the real-time heat transfer coefficient under various operating conditions and updates it after temperature and flow rate normalization. This update operation does not affect historical contamination thermal resistance records and is only used for subsequent contamination identification. Furthermore, the control can be set to periodically (e.g., every 1000 voyage hours) prompt operators to perform baseline value checks to ensure the long-term accuracy of contamination thermal resistance calculations, through monitoring all sections. Spatial mapping is performed, and the control unit constructs a contamination distribution matrix inside the tube bundle, thereby determining the spatial accumulation state and evolution rate of scaling substances within the tube bundle.

[0043] The flow and cleaning coordinated control module executes targeted intervention commands based on the aforementioned pollution distribution matrix. This module includes a flow distribution adjustment unit and a cleaning component drive unit. In the early or mild stages of pollution formation, the system prioritizes changing the flow field distribution inside the heat exchanger through the flow distribution adjustment unit. Specifically, the system adjusts the opening of the proportional valves in each branch to reduce the pollution thermal resistance. Larger sections receive higher velocity compensation, resulting in a higher flow distribution coefficient. The calculation logic is as follows:

[0044] ;

[0045] In this formula, This determines the traffic weight allocated to that segment. As the flow field enhancement factor, A fixed empirical value of 1.2 is adopted (range 1.0–2.0), which can be manually modified by the operator through the human-machine interface of the control unit. As a preferred solution, the closed-loop feedback optimization module of the control unit will… As an online optimization variable, with the goal of minimizing the total system energy consumption, a gradient descent method is used for dynamic optimization: initial value 1.2, step size 0.01, iterating once every 10 minutes, so that... It automatically adapts to different navigation modes and pollution conditions. Through the above settings, those skilled in the art can directly determine the value of the flow field enhancement factor without creative effort. By increasing the fluid velocity in severely polluted areas, the turbulent shear force generated by the fluid strips deposits from the pipe wall and inhibits the adhesion of new fouling. When the thermal resistance of a certain section of the pollution... When the temperature rises continuously and exceeds the preset safety threshold, the cleaning component drive unit receives a high-level command from the controller, which drives the corresponding cleaning component to start. The operating frequency and reciprocating speed of the cleaning component are dynamically adjusted according to the gradient change of the contamination thermal resistance, thereby achieving precise descaling in a directional and quantitative manner.

[0046] The closed-loop feedback optimization module constructs a comprehensive evaluation function with the objective of minimizing the total system energy consumption. To eliminate dimensional differences between different physical quantities, the function adopts a dimensionless normalization form, dividing each parameter by its corresponding benchmark or limit value to convert it into a relative deviation before weighted summation. The objective function is defined as follows:

[0047]

[0048] in: It is a dimensionless comprehensive cost indicator; the smaller the value, the better the current control strategy. Energy consumption due to increased pumping pressure drop caused by flow rate regulation (unit: kW). The reference pumping power (kW) under rated operating conditions without flow field enhancement is determined by factory testing. The sum of the thermal resistance of all sections due to pollution (unit: ), This is the maximum total contamination thermal resistance allowed by the system (units as above). Exceeding this value requires mechanical cleaning. To clean up the actual average power consumption of the component's mechanical operation (unit: ), ,0 represents the operating power of the cleaning component at its rated frequency (unit: (), obtained from the parameters on the motor nameplate; 1, 2, 3 is a dimensionless weighting factor that is dynamically adjusted according to different navigation modes of the ship, and satisfies... 1+ 2+ Since all terms have been normalized to dimensionless relative values, different physical quantities can be reasonably weighted for comparison, ensuring the mathematical rigor of the optimization problem. The control components optimize control parameters (such as flow field enhancement factors) online using gradient descent or extreme value search methods. (e.g., clearing trigger thresholds, etc.) to make Minimize. Simultaneously, the control components can dynamically adjust the weighting factors according to different ship navigation modes (such as full-load acceleration, economical cruising, and berthing). 1, 2, The possible values ​​of 3,

[0049] Full-load acceleration mode: In this mode, heat exchange efficiency has a significant impact on the power system, therefore the weight of heat exchange efficiency loss is adjusted accordingly. 2 should be set to a higher value, preferably 0.7; the weights of the other two items should be reduced accordingly, specifically set to... 1 = 0.2, 3 = 0.1 (satisfied) 1+ 2+ 3=1).

[0050] Economy Cruise Mode: This mode prioritizes fuel economy, and the proportion of pumping energy consumption needs to be carefully controlled; therefore, the weight of pumping pressure drop energy consumption is also important. 1 should be set to a higher value, 0.6 is recommended; the other two values ​​can be set to [value missing]. 2 = 0.3, 3 = 0.1.

[0051] Parking standby mode: In this mode, the heat exchange load is low, and the power consumption of mechanical cleaning is relatively prominent. Therefore, the power consumption of the cleaning component is weighted. 3. Choose a higher value, 0.4 is recommended; the other two values ​​can be set to [value missing]. 1 = 0.3 2 = 0.3.

[0052] The system monitors the performance indicators after the control is implemented and automatically corrects the flow field enhancement factor and the cleaning trigger threshold using gradient descent or other optimization algorithms. This closed-loop mechanism ensures that the heat exchange device always operates within the characteristic range of optimal energy efficiency under varying operating conditions throughout the ship's entire life cycle.

[0053] The frequency converter inside the power control cabinet is electrically connected to the output of the control unit. By changing the power supply frequency of the drive motor, the reciprocating speed of the cleaning component can be infinitely adjusted. The heat exchanger housing is provided with multiple inspection windows, and transparent sight glasses resistant to high temperature and high pressure are installed at the windows to facilitate manual observation of the macroscopic state of the internal tube bundle. The support platform and the base are also provided with shock-absorbing pads to block the physical interference of the power system vibration on the precision electronic components inside the control unit.

[0054] The adaptive control system inside the control unit also integrates fault self-diagnosis logic. When a logical conflict occurs in the sensor feedback data (such as a mismatch between pressure gradient and flow rate changes), the system automatically switches to a safe operation mode and sends an alarm signal to the ship's central monitoring system. At the same time, the system records the thermal resistance change curves before and after each cleaning operation through a historical operating condition storage unit, and predicts the next optimal cleaning time through big data analysis, thereby upgrading traditional preventive maintenance to predictive maintenance and significantly improving the operational reliability of the ship's power auxiliary system.

[0055] S1. Multi-source operational data acquisition and preprocessing:

[0056] The control unit, connected via electrical signals to temperature sensors, pressure transmitters, electromagnetic flow meters, and encoders of the cleaning components, collects real-time temperature, pressure, and flow parameters of the fluids at the inlet and outlet of the heat exchanger, as well as real-time displacement and load current data of the cleaning components. During the acquisition process, the control unit executes a weighted moving average algorithm to filter the original sampling sequence and uses a preset time weighting coefficient to perform a weighted average of the historical data within the sampling window to obtain synchronous data of temperature, pressure, and flow fields with a high signal-to-noise ratio.

[0057] S2. Identification of contamination thermal resistance distribution:

[0058] The control unit discretizes the heat exchanger tube bundle along the fluid axis into multiple calculation segments, with each segment considered as an independent heat balance unit. First, based on the temperature difference between the inlet and outlet of each segment, as well as the mass flow rate and specific heat capacity at constant pressure of the fluid, the real-time heat exchange of that segment is calculated. Then, the real-time heat transfer coefficient of that segment is obtained by inversion using the logarithmic mean temperature difference principle. This real-time heat transfer coefficient is compared with the pre-stored clean state baseline heat transfer coefficient to calculate the equivalent contamination thermal resistance of that segment. By spatially mapping the contamination thermal resistance of all segments, a contamination distribution matrix inside the tube bundle is constructed, thereby determining the spatial accumulation state and evolution rate of scale within the tube bundle.

[0059] S3. Pollution Status Assessment and Control Mode Selection:

[0060] The control unit determines whether the thermal resistance of each section exceeds the preset safety threshold based on the pollution distribution matrix. If it does not exceed the safety threshold, it is determined to be in the initial or mild stage of pollution and proceeds to step S4 to perform flow coordination control. If it exceeds the safety threshold, it proceeds to step S5 to perform mechanical cleaning coordination control.

[0061] S4, Flow Coordination and Regulation:

[0062] The control unit first changes the flow field distribution inside the heat exchanger through the flow distribution adjustment unit, and adjusts the opening of the proportional valves of each branch so that the section with high pollution thermal resistance can obtain higher flow velocity compensation; the flow weight allocated to each section is determined according to the proportion of the pollution thermal resistance of the section to the total pollution thermal resistance of all sections and the preset flow field enhancement factor; by increasing the fluid velocity in the severely polluted area, turbulent shear force is used to peel off the deposits on the pipe wall and inhibit the adhesion of new dirt; after the execution is completed, proceed to step S6;

[0063] S5. Mechanical cleaning coordinated control:

[0064] The controller sends a high-level command to the cleaning component drive unit, driving the corresponding cleaning component to start; the operating frequency and reciprocating speed of the cleaning component are dynamically adjusted according to the gradient change of the contamination thermal resistance, so as to achieve targeted and quantitative descaling of the contaminated section; after the execution is completed, proceed to step S6.

[0065] S6. Closed-loop feedback and self-learning optimization:

[0066] The control unit constructs a comprehensive evaluation function with the goal of minimizing the total energy consumption of the system. This function includes three items: the energy consumption of pumping pressure drop due to increased flow rate regulation, the compensation for heat exchange efficiency loss due to increased thermal resistance, and the mechanical operation power consumption of the cleaning components. The weighting factors of each item are dynamically adjusted according to different navigation modes of the ship. The control unit monitors the performance index feedback after regulation and uses the gradient descent method to automatically correct the flow field enhancement factor and the cleaning trigger threshold, so that the heat exchange device always operates in the optimal energy efficiency range.

[0067] S6. Fault self-diagnosis and safety protection:

[0068] The integrated fault self-diagnosis logic within the control unit monitors sensor feedback data in real time. When a logical conflict is detected where the pressure gradient and flow rate change do not match, the control unit automatically switches to a safe operating mode and sends an alarm signal to the ship's central monitoring system. At the same time, the control unit records the thermal resistance change curves before and after each cleaning operation through a historical operating condition storage unit, and uses big data analysis to predict the next optimal cleaning time, thus achieving predictive maintenance.

[0069] S8. Repeated execution and dynamic iteration:

[0070] The control unit returns to step S1 and repeats the cycle from S1 to S7 to achieve continuous adaptive cleaning and energy efficiency optimization of the heat exchanger under varying operating conditions throughout its entire life cycle.

[0071] In actual ship operation scenarios, such as when a ship is navigating from a freshwater river into a high-salinity sea area, the rate of salt precipitation in the circulating cooling water increases. At this time, the control unit 6 detects a shift in the temperature gradient of the front section of the heat exchanger 2, and calculates the front thermal resistance using formula 3. The temperature rises rapidly, and the adaptive control system responds immediately. First, it increases the flushing flow rate of the front-end tube bundle using Formula 4, utilizing fluid dynamics to suppress salt crystallization. If the rising thermal resistance is not effectively contained, controller 6 issues a command to cleaning component 3, driving the brush head for directional cleaning. After cleaning, the closed-loop feedback module compares the energy efficiency gain before and after cleaning. If it finds that the cleaning action negatively impacts the overall objective function... If the contribution value is large, the cleaning trigger threshold under this working condition will be automatically lowered to achieve self-evolution of the control logic.

[0072] In addition, the power control cabinet 5 is equipped with a complete electrical protection circuit. When the cleaning component 3 encounters motor stall due to severe blockage of the tube bundle during operation, the abnormal current signal captured by the current transformer will be immediately fed back to the control unit 6. The control unit 6 executes the emergency safety protection logic, stops the operation of the cleaning component 3 on that side, and outputs an alarm signal to the ship's central control room. At the same time, it compensates for the insufficient heat exchange capacity by increasing the flow rate of the unblocked tube bundle, ensuring that the cooling demand of the power system is not affected. Multiple pressure monitoring nodes are also distributed on the shell of the heat exchanger 2. These nodes are connected to the control unit 6 and are used to verify the calculation accuracy of the contamination thermal resistance distribution identification module in real time.

[0073] This invention transforms the passive maintenance of traditional heat exchangers into proactive intelligent management through the organic coordination of the above modules. The stable physical structure formed by the base 1 and the support platform 4, together with the stable power environment provided by the power control cabinet 5, provides reliable operational assurance for the adaptive algorithm within the control unit 6. Through rigorous logical operations of formulas one to five, the device realizes a closed loop from microscopic data acquisition to macroscopic energy efficiency optimization. This control method based on zoned thermal resistance identification and flow cleaning coordination not only improves the heat exchange efficiency of the heat exchanger 2, but also significantly reduces fuel consumption and equipment maintenance costs for ships during ocean voyages.

[0074] In this embodiment, the communication links between the control component 6 and various sensors and actuators adopt a redundant design, which can ensure the accurate transmission of control signals even in a strong electromagnetic interference environment. The brush head of the cleaning component 3 is made of corrosion-resistant and highly elastic composite material. With the displacement control of the precision lead screw, it achieves zero-damage cleaning of the inner wall of the heat exchange tube. Through the continuous operation of the closed-loop feedback and self-learning optimization module, the historical operating data stored in the system provides ship management personnel with an intuitive equipment health status assessment report, which elevates traditional preventive maintenance to the level of predictive maintenance, greatly enhancing the operational safety and economy of the ship's power auxiliary system.

[0075] In summary, the present invention provides a marine energy-saving heat exchange device with tube bundle cleaning function. Through the coordinated work of the base 1, heat exchanger 2, cleaning component 3, support platform 4, power control cabinet 5, and control component 6 with integrated adaptive control system, combined with precise mathematical model and control algorithm, it completely solves the technical problems of difficult scale monitoring, high cleaning energy consumption, and poor adaptability to operating conditions in marine heat exchange equipment. Its technical solution has rigorous logic and stable physical structure, and has significant industrial application value.

[0076] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A marine energy-saving heat exchange device with tube bundle cleaning function, comprising a base (1), characterized in that: A support platform (4) is installed on the top right side of the base (1), a heat exchanger (2) is installed on the left side of the base (1), cleaning components (3) are installed at both ends of the heat exchanger (2), a power control cabinet (5) is installed on the top of the support platform (4), and a control component (6) is provided on the right side of the support platform (4). The control element (6) includes: The multi-source operation data acquisition and preprocessing module is used to acquire the fluid temperature, pressure, and flow parameters of the heat exchanger (2) and the displacement and load current data of the cleaning component (3) in real time, and to filter the acquired data. The pollution thermal resistance distribution identification module is used to discretize the heat exchange tube bundle of the heat exchanger (2) into multiple calculation sections, and obtain the real-time heat transfer coefficient based on the real-time heat exchange of each section, and then calculate the equivalent pollution thermal resistance of each section to construct the pollution distribution matrix. The flow and cleaning coordination control module is used to perform descaling operation by adjusting the flow field distribution or driving the cleaning component (3) according to the pollution distribution matrix; The closed-loop feedback optimization module is used to adjust the parameters of the control strategy with the goal of minimizing the total energy consumption of the system.

2. The ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The multi-source operation data acquisition and preprocessing module is connected to the temperature sensor, pressure transmitter, electromagnetic flow meter arranged on the inlet and outlet pipelines of the heat exchanger (2) via electrical signals, as well as the encoder connected to the cleaning component (3), to acquire fluid temperature, pressure, flow rate and real-time displacement and load current of the cleaning component (3).

3. The ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The pollution thermal resistance distribution identification module discretizes the heat exchange tube bundle of the heat exchanger (2) into multiple independent thermal balance unit segments along the axial flow direction of the fluid, and constructs a pollution distribution matrix inside the tube bundle by spatial mapping of the pollution thermal resistance of each segment, so as to determine the spatial accumulation state and evolution rate of the scale material.

4. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The flow and cleaning coordinated control module includes a flow distribution adjustment unit and a cleaning component drive unit. The flow distribution adjustment unit is used to change the flow field distribution inside the heat exchanger (2) by adjusting the opening of the proportional valves of each branch in the early stage of pollution, so that the section with high pollution thermal resistance can obtain higher flow rate compensation. The cleaning component drive unit is used to drive the corresponding cleaning component (3) to start when the pollution thermal resistance exceeds the preset safety threshold, and dynamically adjust the operating frequency and reciprocating speed of the cleaning component (3) according to the gradient change of the pollution thermal resistance.

5. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The closed-loop feedback optimization module constructs a comprehensive evaluation function with the goal of minimizing the total energy consumption of the system. This function adopts a dimensionless normalized form and includes three terms: the relative value of pumping pressure drop energy consumption due to increased flow rate regulation, the relative value of heat exchange efficiency loss due to increased thermal resistance, and the relative value of mechanical power consumption of cleaning components. These terms are weighted and summed after being divided by their corresponding benchmark or limit values, and the weighting factors of each term are dynamically adjusted according to different navigation modes of the ship.

6. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The control unit (6) also integrates fault self-diagnosis logic, which is used to monitor whether there is a logical conflict in the sensor feedback data, and automatically switch to safe operation mode when a logical conflict is detected, while sending an alarm signal to the ship's central monitoring system.

7. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The control unit (6) also includes a historical operating condition storage unit, which records the thermal resistance change curves before and after each cleaning operation, and uses big data analysis to predict the next optimal cleaning time to achieve predictive maintenance.

8. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The power control cabinet (5) is equipped with a frequency converter driver. The frequency converter driver is electrically connected to the port of the control component (6) for controlling signal output. The cleaning component (3) includes a drive motor, which is used to achieve stepless adjustment of the reciprocating speed of the cleaning component (3) by changing the power supply frequency of the drive motor.

9. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: The heat exchanger (2) has multiple inspection windows on its shell, and a transparent sight glass resistant to high temperature and high pressure is installed at the window.

10. A ship energy-saving heat exchange device with tube bundle cleaning function according to claim 1, characterized in that: A shock-absorbing pad is provided between the support platform (4) and the base (1) to block the physical interference of the power system vibration on the electronic components inside the control component (6).

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