Ultrahigh pressure dust-free metal hose and processing technology

Abstract

The application belongs to the technical field of metal hose processing, and particularly relates to an ultrahigh-pressure dust-free metal hose and a processing technology, which comprises an encryption bellows pipe, the outer part of the encryption bellows pipe is fixed with a net cover, the two ends of the encryption bellows pipe and the net cover are both fixed with an outer sheath, the two ends of the outer sheath are both fixed with a transition reinforcing ring, and the other ends of the two transition reinforcing rings are both fixed with a joint; the waveform structure of the bellows pipe and the welding process are changed, the bellows pipe adopts a dense wave multi-layer structure, a set of reinforcing ring joints is added at the transition of the pipe blank and the joint, the welding seam is more firm, the product is more uniform in stress, and when producing and processing, the prepared cleaning liquid is used to clean the pipe blank, the net body and the joint, so that the generated oil stains, dust and other attachments in the forming and processing process can be effectively removed.

Description

Technical Field

[0001] This invention relates to the field of metal hose processing technology, specifically to an ultra-high pressure dust-free metal hose and its processing technology. Background Technology

[0002] Metal flexible hoses are an important component in the connection pipelines of modern industrial equipment. They are used as protective conduits for wires and cables, signal wires and cables of automated instruments, and shower hoses in residential applications, with sizes ranging from 3mm to 150mm. Small-diameter metal flexible hoses are mainly used for the protection of sensing circuits in precision optical scales and industrial sensors.

[0003] However, existing metal hoses still have the following technical problems: The existing metal hoses have a maximum pressure of 25MPa and a burst pressure of 60MPa, which can no longer meet the requirements of related fields. Their pressure resistance and burst pressure are relatively small, resulting in significant limitations in their use.

[0004] Therefore, an ultra-high pressure dust-free metal hose and its processing technology are proposed to solve the above-mentioned problems. Summary of the Invention

[0005] The purpose of this invention is to provide an ultra-high pressure dust-free metal hose and its processing technology to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an ultra-high pressure dust-free metal hose, comprising a densified corrugated tube, a mesh sleeve fixed to the outside of the densified corrugated tube, an outer sheath fixed to both ends of the densified corrugated tube and the mesh sleeve, a transition reinforcing ring fixed to both ends of the outer sheath, and a connector fixed to the other end of each of the two transition reinforcing rings.

[0007] A processing technology for ultra-high pressure dust-free metal hoses, the specific steps of which are as follows: Step 1: Incoming Inspection of Corrugated Pipes: 316L stainless steel corrugated pipes are selected as raw materials. Before processing, the corrugated pipes undergo comprehensive non-destructive testing. An industrial endoscope with a magnification of no less than 10x is used to visually inspect the inner cavity and outer surface of the corrugated pipes. High-precision vernier calipers are used for sampling and full inspection of the corrugated pipe diameter, strictly controlling the diameter to 8cm to ensure consistency. A portable direct-reading spectrometer is used to re-measure the spectral properties of the corrugated pipe material. Step 2, Dense Wave Processing: The qualified corrugated pipes are subjected to dense wave shaping. After the dense wave processing is completed, the inner cavity and appearance of the corrugated pipes are visually inspected again. Step 3: Multi-layer steel wire mesh processing: Before weaving, the material of the steel wire is re-inspected. The material of the steel wire is re-tested with a spectrometer to ensure that the steel wire is also made of 316L stainless steel. The material certificate and mechanical performance test report of the steel wire are verified. After the re-inspection is completed, the mesh is woven. Step 4, Reinforcing Sleeve Cutting: 316L stainless steel reinforcing sleeves are selected as end connectors for reinforcement. Before cutting, the material of the reinforcing sleeve is re-verified using a spectrometer. The reinforcing sleeve is placed stably in the positioning position of the fixed tooling and cold-cut using a dust-free special cutting machine. After cutting, the dimensions of the reinforcing sleeve are checked again to ensure that the cutting dimensions are accurate, the end face is flat, and there is no deformation or collapse. Step 5: End clamp crimping: According to the hose assembly process requirements, pre-adjust the crimping pressure, crimping stroke and closing size of the crimping machine to accurately crimp the outer diameter of the reinforcing sleeve to 19±0.1mm. After crimping, use an ultra-fine grinding and polishing machine to mirror polish the crimping marks on the outer circle of the reinforcing sleeve to eliminate indentations and dents. Step Six: High-precision argon arc welding: Before welding, the area to be welded is preheated for 30 minutes at a temperature of 50℃±5℃. Before welding, the outer wall of the reinforcing sleeve is polished again to remove impurities and oxide scale. After welding, the welded pipe is retested using a spectrometer to ensure that the pipe is made of 316L stainless steel. Step 7: Air tightness test: To ensure the sealing performance of the hose, a 100% air tightness test is performed on the finished metal hose; Step 8: Pressure resistance test: According to the batch sampling standard, no less than 3% of the finished hoses from each production batch shall be sampled for hydraulic strength test to verify the hose's ability to resist high pressure deformation. Step Nine: Passivation and Cleaning Treatment: In order to meet the ultra-high pressure dust-free use standard, the welded and processed hoses are subjected to passivation and cleaning treatment; Step 10: High-purity water rinsing treatment: After passivation, the inner and outer walls of the hose are repeatedly rinsed with industrial high-purity water under high pressure. After rinsing, a dust-free air-drying treatment is carried out to ensure that the inner wall of the hose is dry, clean and free of foreign matter, and finally the ultra-high pressure dust-free metal hose processing and preparation is completed.

[0008] Preferably, in step one, the specific content of visual inspection of the inner cavity and outer surface of the corrugated pipe using an industrial endoscope is as follows: Strictly check for burrs, metal peeling, oxide scale, processing cracks, rust spots, hard scratches, pits, sharp protrusions, and other surface defects on the inner and outer surfaces to ensure that the inner and outer walls of the corrugated pipe are smooth and free of flaws. The specific content of sampling and full inspection of the corrugated pipe diameter using high-precision vernier calipers is as follows: Verify the raw material material certificate to ensure that the raw material is standard 316L austenitic stainless steel. The non-metallic inclusion content of the raw material is strictly tested and rated according to GB / T10561, and the inclusion grade must not exceed 1.5 to avoid impurities causing high-pressure bursts, corrosion leaks, etc. All inspection procedures are properly recorded and inspection reports are retained. Unqualified raw materials are directly isolated and returned, and are strictly prohibited from being used in production.

[0009] Preferably, in step two, the specific steps of the dense corrugation forming process are as follows: First, the special dense corrugation core rod is smoothly inserted into the inside of the corrugated pipe to ensure that the core rod and the corrugated pipe are coaxial and to avoid eccentric processing that causes wear on one side of the pipe wall. Then, the dense corrugation forming machine is started to perform compression dense corrugation processing on the corrugated pipe with an original length of 3.2±0.1m, and the pipe is processed to 2±0.1m. The dense corrugation processing changes the corrugated pipe's wave pitch and wave height structure, thereby improving the overall flexibility, deformation resistance and structural compactness of the corrugated pipe. The visual inspection of the inner cavity and appearance of the corrugated pipe includes: the processed surface must not have indentations, obvious scratches, wrinkles, cracks or other processing defects, and the corrugated pipe waveform must be uniform and consistent with the regular arrangement of the wave pitch, so as to lay the structural foundation for subsequent braiding and crimping processes.

[0010] Preferably, in step three, the mesh is constructed using a three-layer composite woven mesh structure. The specifications and weaving parameters of the three layers of wire are as follows: the first layer has a wire diameter of 0.3mm, 24 strands, 8 wires per strand, and a weaving angle of 54°; the second layer has a wire diameter of 0.4mm, 18 strands, 6 wires per strand, and a weaving angle of 45°; and the third layer has a wire diameter of 0.5mm, 12 strands, 4 wires per strand, and a weaving angle of 38°. The three layers of steel wire are interwoven layer by layer from the inside out. During the weaving process, the tension is kept uniform and the arrangement is tight to avoid uneven tension of the steel wires. After weaving, the appearance of the mesh sleeve is checked manually with a magnifying glass. Defects such as broken wires, missing wires, skipped wires, looseness, and bulges are strictly prohibited to ensure that the mesh sleeve covers tightly and the surface is flat, thereby improving the overall tensile and burst resistance of the hose.

[0011] Preferably, in step four, when processing the reinforcing sleeve, the mixing of materials should be avoided. A precision caliper should be used to check the inner and outer diameters of the reinforcing sleeve to ensure that the inner diameter is 18±0.1mm and the outer diameter is 21±0.1mm. The dimensional deviation should be strictly controlled within the tolerance range. According to the production and processing drawings, a high-precision tape measure should be used to accurately measure the cutting length, and an oil-based marker should be used to make clear marks. The marking positions should avoid the welding area and the crimping area to prevent the marks from contaminating the welding seam. When using a cutting machine for cold cutting, control the cutting speed during the cutting process to avoid the formation of oxide scale due to high-temperature oxidation.

[0012] Preferably, in step five, during the end clamping process, the assembly gap between the reinforcing sleeve and the outer mesh sleeve is eliminated by mechanical clamping, so as to achieve a tight fit between the mesh sleeve, the corrugated pipe, and the reinforcing sleeve, preventing loosening and slippage under high pressure conditions. A professional fitter manually trims and deburrs the blanking port of the reinforcing sleeve and the port of the corrugated pipe, and grinds to eliminate the flared edges and sharp corners of the corrugated pipe, ensuring that the port is smooth and burr-free, avoiding sharp parts from scratching the sealing structure and affecting the dust-free cleanliness. After processing, the appearance of the reinforcing sleeve is inspected, requiring that the outer wall be bright and flat, without obvious clamping marks, burrs, or sharp corners.

[0013] Preferably, in step six, during argon arc welding, environmental conditions are strictly controlled. The welding environment temperature shall not be lower than 15°C and the relative humidity of the ambient air shall not be greater than 90% to prevent welding porosity and cracks from occurring in a low-temperature and humid environment. The welding process adopts a three-in-one high-purity argon welding process. First, the root pass is welded, with the welding current controlled at 60A-80A. The welding shielding gas is 99.99% high-purity argon, with a constant argon flow rate of 10L / min. The root pass weld is smooth and uniform, without burn-through or slag inclusion. After the root pass is completed, the pipe fitting is butt welded. The pipe fitting and the pipe blank are fixed in advance using external positioning fixtures to ensure consistent coaxiality and prevent welding eccentricity. First, the connection is pre-fixed by circumferential spot welding, and then the full weld is performed. The welding current is adjusted to 100A-160A, and the argon flow rate is maintained at 10L / min. After the welding is completed, the weld is ground and polished layer by layer to make the weld smooth, free of weld beads, weld slag, porosity, and cracks.

[0014] Preferably, in step seven, the specific contents of the airtightness test are as follows: A special airtightness sealing fixture is used to clamp and fix both ends of the hose. High-purity argon is used as the test medium. The water immersion test is conducted, with the test pressure set at 10 MPa and the pressure holding time at 5 minutes. During the test, the surface of the immersed hose is observed throughout. No air bubbles should be generated on the hose wall, weld, or connection port. If air bubbles overflow during the test, the product is immediately isolated and stored, a non-conforming label is affixed, and it is reworked separately. Products that cannot be reworked are scrapped. Products that pass the airtightness test are uniformly classified and stored to ensure no air leakage or micro-seepage sealing defects.

[0015] Preferably, in step eight, the specific content of the pressure resistance strength sampling test is as follows: A special strength testing fixture is used to seal the connecting hose. The test pressure is set to 1.5 times the rated working pressure and maintained for 5 minutes. The appearance and sealing status of the hose are observed. During the test, the hose must not exhibit bulging, deformation, elongation, leakage, or cracking. If the sample shows deformation or leakage, the sampling of this batch of products is immediately doubled. If unqualified samples are still found after double sampling, the entire batch of products is deemed scrapped to prevent unqualified high-pressure hoses from entering the market. The strength test data is recorded one by one, and a batch quality ledger is established. During passivation cleaning, the cleaning area should be kept dust-free and clean. The processing fixtures, jigs, and tools should be wiped clean and dry in advance to remove dust and oil. The use cycle of the passivation cleaning solution should be strictly controlled. The cleaning solution should not be used for cleaning this model of high-precision metal hose after it has been opened and stored for more than 1 day. After cleaning 100 hoses, replace the passivation cleaning solution with a brand new one to prevent the accumulation of impurities in the cleaning solution from causing secondary pollution. During the passivation process, the oxide layer, free iron ions, and surface oil stains inside the hose wall are removed, improving the corrosion resistance of stainless steel and ensuring that the inner wall of the hose is clean, free of precipitation, and free of dust residue. During high-purity water rinsing, the rinsing environment should be kept dust-free and sealed, and tools should be free of oil and impurities. The cleaning solution replacement standard should be strictly followed to avoid waste liquid contamination. High-purity water rinsing thoroughly removes residual passivation solution, fine dust, metal particles, and impurities from inside the hose.

[0016] Compared with the prior art, the beneficial effects of the present invention are: This application modifies the waveform structure and welding process of the corrugated pipe, adopting a dense, multi-layered corrugated structure. A set of reinforcing ring joints is added at the transition between the pipe blank and the joint, making the weld stronger and the product more evenly stressed. During production and processing, a specially formulated cleaning solution is used to clean the pipe blank, mesh, and joints, ensuring that oil, dust, and other adhering substances generated during molding and processing can be effectively removed, increasing gloss. The design operating pressure and burst pressure are more than doubled compared to relevant standards, resulting in significant performance improvements. The service life is extended from 1-3 months to over 6 months, saving costs and improving work efficiency, thus demonstrating positive social impact. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of this metal flexible hose; Figure 2 This is a flowchart of the processing steps for this metal hose.

[0018] In the diagram: 1. Encrypted corrugated pipe, 2. Mesh sleeve, 3. Outer sheath, 4. Transition reinforcing ring, 5. Joint. Detailed Implementation

[0019] 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.

[0020] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0021] Example:

[0022] Please see Figure 1-2 The present invention provides a technical solution: An ultra-high pressure dust-free metal hose includes a densified corrugated pipe 1, a mesh sleeve 2 fixed to the outside of the densified corrugated pipe 1, an outer sheath 3 fixed to both ends of the densified corrugated pipe 1 and the mesh sleeve 2, a transition reinforcing ring 4 fixed to both ends of the outer sheath 3, and a connector 5 fixed to the other end of each of the two transition reinforcing rings 4.

[0023] A processing technology for ultra-high pressure dust-free metal hoses, the specific steps of which are as follows: Step 1: Incoming Inspection of Corrugated Pipes: 316L stainless steel corrugated pipes are selected as raw materials. Before processing, the corrugated pipes undergo comprehensive non-destructive testing. An industrial endoscope with a magnification of at least 10x is used to visually inspect the inner cavity and outer surface of the corrugated pipes. High-precision vernier calipers are used for sampling and full inspection of the corrugated pipe diameter, strictly controlling the diameter to 8cm to ensure consistency. A portable direct-reading spectrometer is used to re-measure the spectral density of the corrugated pipe material. By controlling the quality of raw materials from the source, and through triple testing using endoscopy, calipers, and spectrometers, corrugated pipes with cracks, burrs, oxide scale, or excessive inclusions are rejected. Strict control is maintained on the material grade of 316L and the level of inclusions is limited to prevent inherent defects in the raw materials from causing high-pressure bursts, corrosion leaks, and ensuring the pipe's basic high-pressure and corrosion resistance properties. Inspection data is also retained to achieve product quality traceability. Step 2, Dense Wave Processing: The qualified corrugated pipes undergo dense wave shaping. After dense wave processing, the inner cavity and appearance of the corrugated pipe are visually inspected again. The original corrugated pipe is compressed with dense waves to change the corrugation structure, reduce the pipe length, and improve the flexibility, deformation resistance, and structural compactness of the corrugated pipe. This ensures that the corrugations are evenly and regularly arranged, eliminates eccentric wear during processing, and enables the corrugated pipe to withstand high-frequency bending and high-pressure impact, adapting to ultra-high pressure repeated deformation conditions, and providing a stable structural foundation for subsequent braiding and crimping. Step 3: Multi-layer steel wire mesh processing: Before meshing, the material of the braided steel wire is re-inspected. A spectrometer is used to re-test the steel wire material to ensure that the steel wire is also made of 316L stainless steel. The steel wire material certificate and mechanical property test report are verified to ensure that the steel wire's corrosion resistance and tensile strength meet the requirements of ultra-high pressure conditions. The mechanical indicators of steel wire diameter, tensile strength, and yield strength are strictly checked. After the re-inspection is completed, the mesh is woven. A three-layer differentiated steel wire interlaced braiding structure is adopted, using steel wires of different diameters, strand numbers, and braiding angles to form a composite protective mesh sleeve. This improves the radial pressure resistance and axial tensile strength of the hose, limits the high-pressure expansion and deformation of the corrugated pipe, and prevents high-pressure pipe bursting. At the same time, the mesh sleeve tightly wraps around the pipe body, protects the outer wall of the corrugated pipe, reduces friction damage, and improves the overall pressure resistance and service life. Step 4: Reinforcing Sleeve Cutting and Processing: 316L stainless steel reinforcing sleeves are selected as the end connector reinforcement components. Before cutting, the material of the reinforcing sleeve is re-verified using a spectrometer. The reinforcing sleeve is placed stably in the positioning position of the fixed tooling, and cold-cut using a dust-free special cutting machine. After cutting, the dimensions of the reinforcing sleeve are checked again to ensure accurate dimensions, flat end faces, no deformation, and no collapsed edges. As a key reinforcement component for end stress, the reinforcing sleeve is ensured to have high dimensional accuracy and a flat end face without oxide scale through material verification, precise dimensional control, and cold cutting. This avoids oxidation impurities generated by high-temperature cutting, preventing slag inclusions and incomplete welds in later welding. The cutting position is accurately marked to avoid welding areas and prevent oil stains from contaminating the weld, ensuring the end connection strength and welding cleanliness. Step 5: End clamp crimping: According to the hose assembly process requirements, pre-adjust the crimping pressure, crimping stroke, and closing size of the crimping machine to accurately crimp the outer diameter of the reinforcing sleeve to 19±0.1mm. After crimping, use an ultra-fine abrasive polishing machine to mirror-polish the crimping marks on the outer circle of the reinforcing sleeve to eliminate indentations and dents. Precise mechanical crimping eliminates the assembly gap between the reinforcing sleeve, the braided sleeve, and the corrugated pipe, ensuring that the three fit tightly together to prevent loosening or slippage under high-pressure media impact. After crimping, polishing eliminates indentations, and a fitter removes burrs and folds from the ends to ensure that the ends are smooth and without sharp corners, avoiding sharp structures from scratching the pipe sealing surface, while also meeting the cleanliness requirements of a smooth inner wall and no impurities in the dust-free pipeline. Step Six: High-Precision Argon Arc Welding: Before welding, the area to be welded is preheated for 30 minutes at a temperature controlled at 50℃±5℃ to reduce welding temperature stress and prevent deformation. Before welding, the outer wall of the reinforcing sleeve is polished again to remove impurities and oxide scale, ensuring a clean welding surface. After welding, a spectrometer is used to re-inspect the material of the welded connector to ensure it is 316L stainless steel. All welding parameters are recorded and archived to ensure traceability for each product. Welding temperature and humidity are strictly controlled, and the preheating process reduces welding stress, preventing porosity and cracks in the weld. Layered argon arc welding is used: the root pass ensures sealing, and the full pass ensures connection strength. High-purity argon gas protection prevents weld oxidation, and external positioning fixtures ensure coaxiality, preventing stress concentration caused by welding eccentricity. The weld is ground smooth, eliminating slag and protrusions, meeting the standards for clean pipelines with no precipitation and no impurities. Step 7: Air Tightness Test: To ensure the sealing performance of the hose, a 100% air tightness test is conducted on the finished metal hose; the finished hose undergoes a 100% air tightness test, using high-pressure argon immersion in water to check for defects such as micropores, weld gaps, and assembly gaps that are not visible to the naked eye; unqualified products are promptly isolated to prevent micro-leaking products from flowing into the dust-free high-pressure pipeline, ensuring that the hose remains airtight for a long time under high-purity gas and clean fluid conditions; Step 8: Pressure Resistance Sampling Test: According to the batch sampling inspection standard, no less than 3% of the finished hoses from each production batch are randomly selected for hydraulic strength testing to verify the hose's resistance to high-pressure deformation; a pressure resistance test is conducted using 1.5 times the rated pressure to verify the hose's ultimate pressure bearing capacity and structural stability; through batch sampling inspection, double sampling inspection, and batch scrapping system, production quality is strictly controlled, hidden process defects in mass production are identified, and bulging, deformation, and hose bursting accidents during high-pressure use are avoided, thereby improving product safety and reliability; Step Nine: Passivation Cleaning Treatment: To meet the ultra-high pressure and dust-free operation standards, the welded and processed hoses undergo passivation cleaning treatment. Passivation treatment removes the oxide layer, free iron ions, oil stains and impurities from the surface of the hose, forming a dense passivation film on the stainless steel surface to improve corrosion resistance and rust resistance. The usage cycle of the cleaning solution is strictly limited to avoid secondary pollution from waste liquid impurities, ensuring that there is no metal precipitation or dust residue on the inner wall of the hose, meeting the requirements for use in dust-free ultra-high clean pipelines. Step 10: High-purity water rinsing: After passivation, the inner and outer walls of the hose are repeatedly rinsed under high pressure with industrial high-purity water. After rinsing, a dust-free air-drying process is performed to ensure that the inner wall of the hose is dry, clean, and free of foreign matter, thus completing the processing and preparation of the ultra-high pressure dust-free metal hose. High-pressure pure water thoroughly rinses away residual passivation solution, metal particles, and fine dust, combined with a dust-free air-drying process, ensuring that the inner wall of the hose is dry, clean, and free of any residual contaminants; preventing dust shedding and impurity precipitation during later use, making it suitable for high-cleanliness applications such as semiconductors, high-purity gases, and pharmaceuticals.

[0024] In step one, the specific details of visually inspecting the inner cavity and outer surface of the corrugated pipe using an industrial endoscope are as follows: Strictly inspect the inner cavity and outer surface for burrs, metal peeling, oxide scale, processing cracks, rust spots, hard scratches, pits, sharp protrusions, and other surface defects to ensure the inner and outer walls of the corrugated pipe are smooth and free of flaws. The specific details of sampling and full inspection of the corrugated pipe diameter using high-precision vernier calipers are as follows: Verify the raw material certificate to ensure that the raw material is standard 316L austenitic stainless steel. The non-metallic inclusion content of the raw material must be strictly tested and rated according to GB / T10561, with the inclusion grade not exceeding 1.5 to avoid impurities causing high-pressure bursts, corrosion leaks, etc. All inspection procedures must be properly recorded and inspection reports retained. Unqualified raw materials must be directly isolated and returned, and are strictly prohibited from being used in production. The system limits the types of defects detected by endoscopes and sets standards for the rating of inclusions. It strictly controls impurities and cracks at the raw material level, solving the problems of high impurities, easy corrosion, and high-pressure bursting in ordinary metal hoses. This improves the consistency and safety of the hoses, and the test data is retained and traceable, facilitating quality control.

[0025] In step two, the specific steps of the dense corrugation forming process are as follows: First, the special dense corrugation core rod is smoothly inserted into the inside of the corrugated pipe to ensure that the core rod and the corrugated pipe are coaxial and to avoid eccentric processing that causes wear on one side of the pipe wall. Then, the dense corrugation forming machine is started to compress and densely corrugate the original length of the corrugated pipe of 3.2±0.1m to 2±0.1m. The dense corrugation process changes the corrugated pipe's wave pitch and wave height structure, thereby improving the overall flexibility, deformation resistance and structural compactness of the corrugated pipe. The visual inspection of the corrugated pipe's inner cavity and exterior includes: ensuring that the machined surface is free of indentations, obvious scratches, wrinkles, cracks, and other processing defects; guaranteeing a uniform and consistent corrugated waveform with a regular wave pitch arrangement to lay the structural foundation for subsequent braiding and crimping processes. Limiting the length of dense corrugations and ensuring coaxiality of the threaded rods are crucial to avoid eccentric wear during processing, resulting in a uniform corrugated waveform and consistent elasticity. Compared to ordinary corrugated pipes, this structure exhibits stronger resistance to fatigue bending, is less prone to cracking under repeated high-pressure deformation, and demonstrates higher structural stability.

[0026] In step three, the mesh is made using a three-layer composite woven mesh structure. The specifications and weaving parameters of the three layers of steel wire are as follows: the first layer has a steel wire diameter of 0.3mm, 24 strands, 8 wires per strand, and a weaving angle of 54°; the second layer has a steel wire diameter of 0.4mm, 18 strands, 6 wires per strand, and a weaving angle of 45°; the third layer has a steel wire diameter of 0.5mm, 12 strands, 4 wires per strand, and a weaving angle of 38°. Three layers of steel wire are interwoven layer by layer from the inside out. During the weaving process, uniform tension and tight arrangement are maintained to avoid uneven wire tension. After weaving, the appearance of the mesh is manually inspected using a magnifying glass. Defects such as broken wires, missing wires, skipped wires, looseness, and bulges are strictly prohibited. This ensures a tight mesh covering and a smooth surface, improving the overall tensile and burst resistance of the hose. The three layers of steel wire are differentiated in thickness and angle, with a soft and conforming inner layer, a pressure-bearing middle layer, and a protective outer layer, resulting in uniform stress distribution. This overcomes the shortcomings of single-layer braided mesh, such as weak pressure resistance, easy wire breakage, and loose covering, significantly increasing burst pressure while maintaining hose flexibility and a smooth, aesthetically pleasing appearance.

[0027] In step four, during the blanking process of the reinforcing sleeve, the mixing of materials must be prevented. A precision caliper is used to check the inner and outer diameters of the reinforcing sleeve to ensure that the inner diameter is 18±0.1mm and the outer diameter is 21±0.1mm. The dimensional deviation is strictly controlled within the tolerance range. According to the production and processing drawings, a high-precision tape measure is used to accurately measure the blanking length, and an oil-based marker is used to make clear marks. The marking positions should avoid the welding area and the crimping area to prevent the marks from contaminating the welding seam. When using a cutting machine for cold cutting, the cutting speed should be controlled during the cutting process to avoid the formation of oxide scale due to high-temperature oxidation. Precisely defining the tolerances of the reinforcing sleeve, marking positions, and cold cutting processes prevents impurities from high-temperature oxidation and avoids oil contamination of the weld seam. This ensures uniform dimensions of the end connectors, small assembly gaps, higher weld strength, and eliminates the risk of end breakage and disengagement.

[0028] In step five, during the end clamping process, mechanical clamping eliminates the assembly gap between the reinforcing sleeve and the outer mesh sleeve, ensuring a tight fit between the mesh sleeve, corrugated pipe, and reinforcing sleeve. This prevents loosening and slippage under high-pressure conditions. A professional fitter manually trims and deburrs the reinforcing sleeve's blanking port and the corrugated pipe's port, grinding away any flared edges and sharp corners to ensure a smooth, burr-free surface. This prevents sharp edges from damaging the sealing structure and affecting cleanliness. After processing, the reinforcing sleeve's appearance is inspected, requiring a bright, smooth outer wall without obvious clamping marks, burrs, or sharp corners. Eliminating gaps in the multi-layered structure enhances overall integrity, preventing delamination and slippage under high pressure. Deburring and removing flared edges at the ports ensures a smooth inner wall transition, eliminating dead corners and dust accumulation, making it compatible with cleanroom piping. Polishing the exterior removes indentations, simultaneously improving corrosion resistance and aesthetics.

[0029] In step six, during argon arc welding, environmental conditions are strictly controlled. The welding environment temperature must not be lower than 15°C and the relative humidity of the ambient air must not be higher than 90% to prevent welding porosity and cracks caused by low temperature and humid environment. Limiting temperature and humidity, preheating temperature, and layered welding parameters solves the problems of porosity, incomplete welding, and rough weld that are easy to occur in ordinary welding. The welding process employs a three-in-one high-purity argon welding process. First, a root pass is performed, with the welding current controlled at 60A-80A. The shielding gas used is 99.99% pure argon, with a constant argon flow rate of 10L / min. The root pass weld is smooth and uniform, without burn-through or slag inclusions. After the root pass, the connecting pipe is butt-welded. External positioning fixtures are used to pre-fix the connecting pipe and the pipe blank to ensure coaxiality and prevent welding eccentricity. First, circumferential spot welding is performed to pre-fix the connection, followed by full welding. The welding current is adjusted to 100A-160A, with a continuous argon flow rate of 10L / min. After welding, the weld is ground and polished layer by layer to ensure a smooth, flat weld free of weld beads, slag, porosity, and cracks. The weld is smooth without protrusions, with a smooth inner wall that does not easily accumulate dust, high coaxiality, uniform stress, high weld strength, and high cleanliness.

[0030] In step seven, the specific contents of the airtightness test are as follows: A special airtightness sealing fixture is used to clamp and fix both ends of the hose. High-purity argon is used as the test medium. The water immersion test is conducted, with the test pressure set at 10 MPa and the pressure holding time at 5 minutes. During the test, the surface of the immersed hose is observed throughout. No air bubbles should be generated on the hose wall, weld, or connection port. If air bubbles overflow during the test, the product is immediately isolated and stored, labeled as defective, and reworked separately. Products that cannot be reworked are scrapped. Products that pass the airtightness test are uniformly categorized and stored to ensure no air leakage or micro-seepage sealing defects.

[0031] In step eight, the specific contents of the pressure resistance strength sampling test are as follows: A special strength testing fixture is used to seal the connecting hose. The test pressure is set to 1.5 times the rated working pressure and maintained for 5 minutes. The appearance and sealing condition of the hose are observed. During the test, the hose must not exhibit bulging, deformation, elongation, leakage, or cracking. If any sample shows deformation or leakage, the sampling of this batch of products is immediately doubled. If unqualified samples are still found after double sampling, the entire batch of products is deemed scrapped to prevent unqualified high-pressure hoses from entering the market. The strength test data is recorded one by one, and a batch quality ledger is established. During passivation cleaning, the cleaning area should be kept dust-free and clean. The processing fixtures, jigs, and tools should be wiped clean and dry in advance to remove dust and oil. The use cycle of the passivation cleaning solution should be strictly controlled. The cleaning solution should not be used for cleaning this model of high-precision metal hose after it has been opened and stored for more than 1 day. After cleaning 100 hoses, replace the passivation cleaning solution with a brand new one to prevent the accumulation of impurities in the cleaning solution from causing secondary pollution. During the passivation process, the oxide layer, free iron ions, and surface oil stains inside the hose wall are removed, improving the corrosion resistance of stainless steel and ensuring that the inner wall of the hose is clean, free of precipitation, and free of dust residue. During high-purity water rinsing, the rinsing environment should be kept dust-free and sealed, and tools should be free of oil and impurities. The cleaning solution replacement standard should be strictly followed to avoid waste liquid contamination. High-purity water rinsing thoroughly removes residual passivation solution, fine dust, metal particles, and impurities from inside the hose.

[0032] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0033] 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. An ultra-high pressure dust-free metal hose, comprising a densely corrugated pipe (1), characterized in that, The encrypted corrugated pipe (1) is fixed with a mesh sleeve (2) on the outside. Both ends of the encrypted corrugated pipe (1) and the mesh sleeve (2) are fixed with an outer sheath (3). Both ends of the outer sheath (3) are fixed with transition reinforcing rings (4). The other ends of the two transition reinforcing rings (4) are fixed with a connector (5).

2. A processing method for the ultra-high pressure dust-free metal hose according to claim 1, characterized in that: The specific steps of this processing technique are as follows: Step 1: Incoming Inspection of Corrugated Pipes: 316L stainless steel corrugated pipes are selected as raw materials. Before processing, the corrugated pipes undergo comprehensive non-destructive testing. An industrial endoscope with a magnification of no less than 10x is used to visually inspect the inner cavity and outer surface of the corrugated pipes. High-precision vernier calipers are used to sample and fully inspect the pipe diameter, strictly controlling the diameter to 8cm to ensure consistency. A portable direct-reading spectrometer is used to re-measure the spectral properties of the corrugated pipe material. Step 2, Dense Wave Processing: The qualified corrugated pipes are subjected to dense wave shaping. After the dense wave processing is completed, the inner cavity and appearance of the corrugated pipes are visually inspected again. Step 3: Multi-layer steel wire mesh processing: Before weaving, the material of the steel wire is re-inspected. The material of the steel wire is re-tested with a spectrometer to ensure that the steel wire is also made of 316L stainless steel. The material certificate and mechanical performance test report of the steel wire are verified. After the re-inspection is completed, the mesh is woven. Step 4, Reinforcing Sleeve Cutting: 316L stainless steel reinforcing sleeves are selected as end connectors for reinforcement. Before cutting, the material of the reinforcing sleeve is re-verified using a spectrometer. The reinforcing sleeve is placed stably in the positioning position of the fixed tooling and cold-cut using a dust-free special cutting machine. After cutting, the dimensions of the reinforcing sleeve are checked again to ensure that the cutting dimensions are accurate, the end face is flat, and there is no deformation or collapse. Step 5: End clamp crimping: According to the hose assembly process requirements, pre-adjust the crimping pressure, crimping stroke and closing size of the crimping machine to accurately crimp the outer diameter of the reinforcing sleeve to 19±0.1mm. After crimping, use an ultra-fine grinding and polishing machine to mirror polish the crimping marks on the outer circle of the reinforcing sleeve to eliminate indentations and dents. Step Six: High-precision argon arc welding: Before welding, the area to be welded is preheated for 30 minutes at a temperature of 50℃±5℃. Before welding, the outer wall of the reinforcing sleeve is polished again to remove impurities and oxide scale. After welding, the welded pipe is retested using a spectrometer to ensure that the pipe is made of 316L stainless steel. Step 7: Air tightness test: To ensure the sealing performance of the hose, a 100% air tightness test is performed on the finished metal hose; Step 8: Pressure resistance test: According to the batch sampling standard, no less than 3% of the finished hoses from each production batch shall be sampled for hydraulic strength test to verify the hose's ability to resist high pressure deformation. Step Nine: Passivation and Cleaning Treatment: In order to meet the ultra-high pressure dust-free use standard, the welded and processed hoses are subjected to passivation and cleaning treatment; Step 10: High-purity water rinsing treatment: After passivation, the inner and outer walls of the hose are repeatedly rinsed with industrial high-purity water under high pressure. After rinsing, a dust-free air-drying treatment is carried out to ensure that the inner wall of the hose is dry, clean and free of foreign matter, and finally the ultra-high pressure dust-free metal hose processing and preparation is completed.

3. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step one, the specific details of visually inspecting the inner cavity and outer surface of the corrugated pipe using an industrial endoscope are as follows: Strictly inspect the inner cavity and outer surface for burrs, metal peeling, oxide scale, processing cracks, rust spots, hard scratches, pits, sharp protrusions, and other surface defects to ensure the inner and outer walls of the corrugated pipe are smooth and free of flaws. The specific details of sampling and full inspection of the corrugated pipe diameter using high-precision vernier calipers are as follows: Verify the raw material certificate to ensure that the raw material is standard 316L austenitic stainless steel. The non-metallic inclusion content of the raw material must be strictly tested and rated according to GB / T10561, with the inclusion grade not exceeding 1.5 to avoid impurities causing high-pressure bursts, corrosion leaks, etc. All inspection procedures must be properly recorded and inspection reports retained. Unqualified raw materials must be directly isolated and returned, and are strictly prohibited from being used in production.

4. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step two, the specific steps of the dense corrugation forming process are as follows: First, the special dense corrugation core rod is smoothly inserted into the inside of the corrugated pipe to ensure that the core rod and the corrugated pipe are coaxial and to avoid eccentric processing that causes wear on one side of the pipe wall. Then, the dense corrugation forming machine is started to compress and densely corrugate the original length of the corrugated pipe of 3.2±0.1m to 2±0.1m. The dense corrugation process changes the corrugated pipe's wave pitch and wave height structure, thereby improving the overall flexibility, deformation resistance and structural compactness of the corrugated pipe. The visual inspection of the inner cavity and appearance of the corrugated pipe includes: the processed surface must not have indentations, obvious scratches, wrinkles, cracks or other processing defects, and the corrugated pipe waveform must be uniform and consistent with the regular arrangement of the wave pitch, so as to lay the structural foundation for subsequent braiding and crimping processes.

5. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step three, the mesh is made using a three-layer composite woven mesh structure. The specifications and weaving parameters of the three layers of steel wire are as follows: the first layer has a steel wire diameter of 0.3mm, 24 strands, 8 wires per strand, and a weaving angle of 54°; the second layer has a steel wire diameter of 0.4mm, 18 strands, 6 wires per strand, and a weaving angle of 45°; the third layer has a steel wire diameter of 0.5mm, 12 strands, 4 wires per strand, and a weaving angle of 38°. The three layers of steel wire are interwoven layer by layer from the inside out. During the weaving process, the tension is kept uniform and the arrangement is tight to avoid uneven tension of the steel wires. After weaving, the appearance of the mesh sleeve is checked manually with a magnifying glass. Defects such as broken wires, missing wires, skipped wires, looseness, and bulges are strictly prohibited to ensure that the mesh sleeve covers tightly and the surface is flat, thereby improving the overall tensile and burst resistance of the hose.

6. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step four, during the blanking process of the reinforcing sleeve, the mixing of materials must be prevented. A precision caliper is used to check the inner and outer diameters of the reinforcing sleeve to ensure that the inner diameter is 18±0.1mm and the outer diameter is 21±0.1mm. The dimensional deviation is strictly controlled within the tolerance range. According to the production and processing drawings, a high-precision tape measure is used to accurately measure the blanking length, and an oil-based marker is used to make clear marks. The marking positions should avoid the welding area and the crimping area to prevent the marks from contaminating the welding seam. When using a cutting machine for cold cutting, control the cutting speed during the cutting process to avoid the formation of oxide scale due to high-temperature oxidation.

7. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step five, during the end clamping process, the assembly gap between the reinforcing sleeve and the outer mesh sleeve is eliminated by mechanical clamping, so as to achieve a tight fit between the mesh sleeve, the corrugated pipe, and the reinforcing sleeve, preventing loosening and slippage under high pressure conditions. A professional fitter manually trims and deburrs the blanking port of the reinforcing sleeve and the port of the corrugated pipe, and grinds and eliminates the flared edges and sharp corners of the corrugated pipe to ensure that the port is smooth and burr-free, avoiding sharp parts from scratching the sealing structure and affecting the dust-free cleanliness. After processing, the appearance of the reinforcing sleeve is inspected, requiring that the outer wall be bright and flat, without obvious clamping marks, burrs, or sharp corners.

8. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step six, during argon arc welding, environmental conditions must be strictly controlled. The welding environment temperature must not be lower than 15°C and the relative humidity of the ambient air must not be greater than 90% to prevent welding porosity and cracks from occurring in a low-temperature and humid environment. The welding process adopts a three-in-one high-purity argon welding process. First, the root pass is welded, with the welding current controlled at 60A-80A. The welding shielding gas is 99.99% high-purity argon, with a constant argon flow rate of 10L / min. The root pass weld is smooth and uniform, without burn-through or slag inclusion. After the root pass is completed, the pipe fitting is butt welded. The pipe fitting and the pipe blank are fixed in advance using external positioning fixtures to ensure consistent coaxiality and prevent welding eccentricity. First, the connection is pre-fixed by circumferential spot welding, and then the full weld is performed. The welding current is adjusted to 100A-160A, and the argon flow rate is maintained at 10L / min. After the welding is completed, the weld is ground and polished layer by layer to make the weld smooth, free of weld beads, weld slag, porosity, and cracks.

9. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step seven, the specific contents of the airtightness test are as follows: A special airtightness sealing fixture is used to clamp and fix both ends of the hose. High-purity argon is used as the test medium. The water immersion test is conducted, with the test pressure set at 10 MPa and the pressure holding time at 5 minutes. During the test, the surface of the immersed hose is observed throughout. No air bubbles should be generated on the hose wall, weld, or connection port. If air bubbles overflow during the test, the product is immediately isolated and stored, labeled as defective, and reworked separately. Products that cannot be reworked are scrapped. Products that pass the airtightness test are uniformly categorized and stored to ensure no air leakage or micro-seepage sealing defects.

10. The processing technology of an ultra-high pressure dust-free metal hose according to claim 2, characterized in that: In step eight, the specific contents of the pressure resistance strength sampling test are as follows: A special strength testing fixture is used to seal the connecting hose. The test pressure is set to 1.5 times the rated working pressure and maintained for 5 minutes. The appearance and sealing condition of the hose are observed. During the test, the hose must not exhibit bulging, deformation, elongation, leakage, or cracking. If the sample shows deformation or leakage, the sampling of this batch of products is immediately doubled. If unqualified samples are still found after double sampling, the entire batch of products is deemed scrapped to prevent unqualified high-pressure hoses from entering the market. The strength test data is recorded one by one, and a batch quality ledger is established. During passivation cleaning, the cleaning area should be kept dust-free and clean. The processing fixtures, jigs, and tools should be wiped clean and dry in advance to remove dust and oil. The use cycle of the passivation cleaning solution should be strictly controlled. The cleaning solution should not be used for cleaning this model of high-precision metal hose after it has been opened and stored for more than 1 day. After cleaning 100 hoses, replace the passivation cleaning solution with a brand new one to prevent the accumulation of impurities in the cleaning solution from causing secondary pollution. During the passivation process, the oxide layer, free iron ions, and surface oil stains inside the hose wall are removed, improving the corrosion resistance of stainless steel and ensuring that the inner wall of the hose is clean, free of precipitation, and free of dust residue. During high-purity water rinsing, the rinsing environment should be kept dust-free and sealed, and tools should be free of oil and impurities. The cleaning solution replacement standard should be strictly followed to avoid waste liquid contamination. High-purity water rinsing thoroughly removes residual passivation solution, fine dust, metal particles, and impurities from inside the hose.

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