Degreasing agent reactor with self-cleaning function

Abstract

The utility model discloses a degreasant reactor with a self-cleaning function. The degreasant reactor comprises an outer cylinder, a laminated reaction module, a stirring system and an intelligent monitoring system, the inner wall of the outer cylinder is provided with a corrosion-resistant coating, the top is provided with an annular spray pipe, and the bottom is provided with a discharge port; the hollow reaction modules are internally connected in series to form hollow material channels with alternately changed spiral directions, so that the turbulence reaction efficiency is enhanced. A stirring shaft penetrates through the center of the module and is connected with a servo motor through a magnetic coupling coupler, and wear-resistant ceramic bristles are arranged at the ends of paddles and make contact with the inner wall of a channel in a scraping mode. The ultrasonic transducer is circumferentially embedded into the side wall of the outer cylinder, the thickness of residues is monitored in real time by combining with the optical sensor, and a collaborative cleaning program is triggered. The device realizes efficient degreasing reaction and self-maintenance through a dual cleaning mechanism of mechanical scrubbing and ultrasonic cavitation, and is suitable for the field of degreasing agent production.

Description

Technical Field

[0001] This utility model relates to the field of degreasing agent production equipment, and in particular to a degreasing agent reactor with self-cleaning function. Background Technology

[0002] Industrial degreasers are widely used in metal processing, electronics manufacturing, and the automotive industry to remove contaminants such as grease and cutting fluid from material surfaces. Their effectiveness directly impacts the quality of subsequent processes such as electroplating and coating. The production process requires efficient mixing, reaction, and residue removal within a reactor. Traditional degreaser reactors suffer from the following technical bottlenecks: 1. Severe residue accumulation: Grease, particles, and other residues easily adhere to the reactor's inner walls, necessitating frequent shutdowns for manual cleaning, leading to low production efficiency. 2. Low cleaning efficiency: Existing technologies often rely on single cleaning methods (such as mechanical scraping or chemical rinsing), which cannot thoroughly remove stubborn dirt and may cause equipment corrosion. 3. High energy consumption and cost: Mechanical stirring structures are complex and require significant power; ultrasonic cleaning modules are separated from the reaction function, requiring additional equipment, increasing energy consumption and floor space. 4. Insufficient intelligence: Lack of real-time monitoring of residue thickness; cleaning cycles rely on experience, easily leading to over-cleaning or delayed cleaning.

[0003] The self-cleaning reactor disclosed in patent number CN207887165U uses a fixed stirring blade, which cannot reach the complex inner wall of the flow channel, resulting in cleaning dead zones. Therefore, there is an urgent need for a degreasing agent reactor that integrates reaction and self-cleaning functions and intelligent control. Utility Model Content

[0004] The technical problem to be solved by this invention is to overcome the defects of the prior art and provide a degreasing agent reactor with self-cleaning function.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0006] This utility model discloses a degreasing agent reactor with self-cleaning function, comprising: an outer cylinder with a corrosion-resistant coating on its inner wall, a feed inlet and an annular spray pipe at the top, and a discharge outlet at the bottom; the feed inlet is equipped with an electric regulating valve, and the discharge outlet is equipped with a switching valve; at least two hollow reaction modules are stacked inside the outer cylinder, adjacent reaction modules are sealed together by flanges, and internally connected in series to form a spiral hollow material channel, the adjacent sections of the spiral hollow material channel having opposite spiral directions; and a stirring shaft, coaxially penetrating all reaction modules, and connected to a servo motor at the bottom via a magnetic coupling. The magnetic coupling includes a permanent magnet and an armature disk fixed to the output shaft of the servo motor; stirring blades are evenly distributed along the stirring shaft axis, and each stirring blade has horizontal bristles at its end, which contact the inner wall of the spiral hollow material channel and are coated with a wear-resistant ceramic coating; an ultrasonic cleaning module includes an ultrasonic transducer circumferentially embedded in the side wall of the outer cylinder; and an intelligent monitoring system includes an optical sensor installed on the inner wall of the spiral hollow material channel, which is connected to the servo motor controller signal and triggers the cleaning program when the thickness of the residue exceeds a set threshold.

[0007] As a preferred embodiment of this invention, the spiral angle of the reaction module is 30°-60°, and the difference in spiral angle between adjacent reaction modules is greater than 10°.

[0008] As a preferred embodiment of this invention, the wear-resistant ceramic coating is a silicon carbide ceramic coating with a thickness of 50-200 μm and includes a gradient structure.

[0009] As a preferred embodiment of this utility model, the number of ultrasonic transducers is at least three, which are distributed at equal angles and have a working frequency of 20-40kHz.

[0010] As a preferred embodiment of this utility model, the optical sensor is a laser triangulation sensor with a measurement accuracy of ±0.1mm.

[0011] As a preferred technical solution of this utility model, the nozzle of the annular spray pipe is a rotatable structure, the spray pressure is 2-5MPa, and the spray direction forms an angle of 15°-30° with the inner wall of the spiral hollow material channel.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0013] 1. High-efficiency mixing and self-cleaning in one: Spiral material channel: The reverse spiral design extends the material residence time and enhances mass transfer efficiency (30°-60° rise angle optimizes fluid turbulence), while forming a continuous inner wall contact surface for easy full coverage cleaning by the bristles; Composite cleaning system: The mechanical scraping of horizontal bristles (silicon carbide coating), ultrasonic cavitation effect (20-40kHz), and high-pressure spray (2-5MPa) work together to improve cleaning efficiency by more than 40% compared to single cleaning methods;

[0014] 2. Modular reaction unit: The stacked flange connection structure supports quick disassembly and replacement, reducing downtime; magnetic coupling drive (temperature resistant above 150℃) avoids leakage risk and extends equipment life; intelligent trigger cleaning program: optical sensors (±0.1mm accuracy) monitor the residue thickness in real time and start cleaning only when actually needed, saving 30%-50% energy compared to traditional timed cleaning;

[0015] 3. Adjustable spray parameters: The nozzle rotation angle (15°-30°) and pressure are adapted to degreasing agents of different viscosities to avoid cleaning blind spots. Attached Figure Description

[0016] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0017] Figure 1 This is a cross-sectional structural diagram of the present invention;

[0018] Figure 2 This is a partial schematic diagram a1 of the present invention;

[0019] Figure 3 This is a partial schematic diagram a2 of the present invention;

[0020] Figure 4 This is the front view of this utility model;

[0021] In the diagram: 1. Outer cylinder; 2. Reaction module; 3. Hollow material channel; 4. Stirring shaft; 5. Magnetic coupling; 6. Servo motor; 7. Stirring blade; 8. Horizontal brush; 9. Feed inlet; 10. Electric regulating valve; 11. Discharge outlet; 12. Ultrasonic transducer; 13. Annular spray pipe; 14. Optical sensor; 15. Flange; 16. Permanent magnet; 17. Armature plate. Detailed Implementation

[0022] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0023] In the attached diagram, all identical reference numerals refer to the same components.

[0024] like Figure 1-4 As shown, this utility model provides a degreasing agent reactor with self-cleaning function, and the specific implementation structure and connection method are as follows:

[0025] Outer Cylinder 1 Assembly: The outer cylinder 1 is a vertical cylindrical structure. The top feed inlet 9 is connected to an electric regulating valve 10 via a flange. The flange sealing surface is machined with concentric corrugated grooves and fitted with a composite sealing gasket. The annular spray pipe 13 is arranged circumferentially along the inner wall of the cylinder. Its branch pipes are connected to the main pipe via tee joints. The nozzles are fixed with quick-release clamps and the spray angle is adjustable. The bottom discharge port 11 is welded to the cylinder via a tapered transition section. The outlet flange is connected to a pneumatic valve, and the valve seat sealing surface is overlaid with a wear-resistant alloy layer. Reaction Module 2 Stacked Structure: The three-layer reaction module 2 is stacked via upper and lower flanges. Fluororubber sealing strips are embedded in the flange sealing grooves and secured with double-headed bolts. The adjacent sections of the spiral hollow material channel 3 inside the module have opposite spiral directions, and the channel joints are machined with guide slopes. The central through-hole of the module is clearance-fitted with the stirring shaft 4, and a self-lubricating bearing is installed inside the through-hole. Stirring Shaft 4 Drive Connection: The stirring shaft 4 passes through all reaction modules 2, and its end is connected to the permanent magnet 16 of the magnetic coupling coupling 5 via a transition flange. The armature disk 17 and the output shaft of the servo motor 6 are keyway-fitted, and the air gap of the coupling is controlled by an adjustable shim set. The stirring blade 7 is connected to the shaft body through a wedge-shaped tenon, and an adjusting shim is set on the side of the tenon. Cleaning mechanism implementation: The bristle 8 substrate is welded to the end of the stirring blade 7, and the silicon carbide fiber bundles are arranged radially, with the fiber length exceeding the inner diameter of the channel 3 to form elastic contact pressure. The ultrasonic transducer 12 is embedded in the mounting hole on the side wall of the outer cylinder 1, and the transducer base is bonded and fixed to the outer cylinder 1 with thermally conductive adhesive. Detection and control system: The optical sensor 14 is fixed to the side wall of the channel 3 through a bracket with a fine-tuning slide, and the sensor probe is calibrated at multiple angles through a ball joint. When the thickness of the residue exceeds the standard, the controller synchronously increases the speed of the servo motor 6 and starts the ultrasonic transducer 12. The usage of this utility model is as follows:

[0026] 1. Degreasing Stage: Material is injected through the feed inlet 9 at the top of the outer cylinder 1, and the electric regulating valve 10 controls the feed rate according to the preset flow rate. The annular spray pipe 13 sprays degreasing agent synchronously, and the nozzle guides the liquid to the inlet of the spiral hollow material channel 3 of the reaction module 2 at a 25° angle; the servo motor 6 drives the stirring shaft 4 to rotate at a speed of 80-120 rpm, driving the stirring blades 7 to shear and mix the material. When the material flows along the spiral hollow material channel 3, due to the alternating spiral direction of the adjacent reaction modules 2 (55° left-hand rotation → 40° right-hand rotation → 35° left-hand rotation), periodic turbulence is formed, which improves the reaction efficiency by more than 40%; the material that has completed the reaction flows into the bottom of the outer cylinder 1 through the end of the spiral hollow material channel 3, and is intermittently discharged through the pneumatic valve of the discharge port 11. The valve opening is adjusted by feedback from the thickness of the residue.

[0027] 2. Self-cleaning trigger stage: Optical sensor 14 scans the inner wall of channel 3 in real time. When the thickness of the residue detected is ≥0.25mm, it sends a signal to the PLC controller. The laser measurement spot diameter of sensor 14 is ≤1mm, and the sampling frequency is 100Hz, ensuring a detection accuracy of ±0.05mm. The controller synchronously performs the following operations: Increase brush speed: Servo motor 6 is accelerated to 150rpm, and the scraping frequency of brush bristles 8 on the inner wall of channel 3 is increased by 2 times; Activate ultrasonic waves: Ultrasonic transducer 12 operates at a frequency of 28kHz, and the micro-jet generated by cavitation effect impacts the dead corner residue; High-pressure spray: Spray pipe 13 is switched to alkaline cleaning solution, and the pressure is increased to 5MPa, and the rotatable nozzle covers the entire circumference of channel 3;

[0028] 3. Wastewater Treatment Stage: The cleaning wastewater is discharged through outlet 11, with a flow rate of 50L / min when the pneumatic valve is fully open. At the end of the discharge, 0.6MPa compressed air is introduced into the outer cylinder 1 to blow away residual droplets in channel 3 through the nozzles of spray pipe 13. After cleaning, when the optical sensor 14 detects that the residual thickness is ≤0.02mm, the controller executes the following: the servo motor 6 slows down to standby mode (30rpm); the ultrasonic transducer 12 is turned off; and the spray pipe 13 switches back to degreasing agent supply, preparing for the next cycle.

[0029] According to the GB / T25146-2010 standard test, this workflow achieves the following: single degreasing operation cycle ≤ 45 minutes (traditional equipment ≥ 70 minutes); self-cleaning program time ≤ 3 minutes, water consumption reduced by 60%; after continuous operation for 200 hours, the wear of brush bristles 8 is < 5%, and there is no visible residue on the inner wall of channel 3.

[0030] This invention is a degreasing agent reactor with self-cleaning function. Through the alternating flow design of the modular reaction module 2 and the spiral hollow material channel 3, combined with the mechanical cleaning of the brush bristles 8 and the cavitation effect of the ultrasonic transducer 12, it achieves efficient degreasing and self-cleaning functions.

[0031] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A degreasing agent reactor with self-cleaning function, characterized in that, The system includes an outer cylinder (1) with a corrosion-resistant coating on its inner wall, a feed inlet (9) and an annular spray pipe (13) at the top, and a discharge outlet (11) at the bottom. The feed inlet (9) is equipped with an electric regulating valve (10), and the discharge outlet (11) is equipped with a switching valve. At least two hollow reaction modules (2) are stacked inside the outer cylinder (1). Adjacent reaction modules (2) are sealed and connected by flanges (15), and are connected in series to form a spiral hollow material channel (3). The adjacent sections of the hollow material channel (3) are spirally connected. The rotation direction is opposite; the stirring shaft (4) coaxially runs through all reaction modules (2), and the bottom is connected to the servo motor (6) through a magnetic coupling coupling (5). The magnetic coupling coupling (5) includes a permanent magnet (16) and an armature disk (17) fixed to the output shaft of the servo motor (6); the stirring blades (7) are evenly distributed along the axial direction of the stirring shaft (4), and each stirring blade (7) has horizontal bristles (8) at its end. The horizontal bristles (8) are in contact with the inner wall of the hollow material channel (3) and are coated with a wear-resistant ceramic coating. The ultrasonic cleaning module includes an ultrasonic transducer (12) circumferentially embedded in the side wall of the outer cylinder (1); the intelligent monitoring system includes an optical sensor (14) installed on the inner wall of the spiral hollow material channel (3), the optical sensor (14) being signal-connected to the servo motor (6) controller, and triggering the cleaning program when the thickness of the residue exceeds a set threshold.

2. The degreasing agent reactor with self-cleaning function according to claim 1, characterized in that, The spiral angle of the reaction module (2) is 30°-60°, and the difference in spiral angle between adjacent reaction modules (2) is greater than 10°.

3. A degreasing agent reactor with self-cleaning function according to claim 1, characterized in that, The wear-resistant ceramic coating is a silicon carbide ceramic coating with a thickness of 50-200 μm and contains a gradient structure.

4. A degreasing agent reactor with self-cleaning function according to claim 1, characterized in that, The number of ultrasonic transducers (12) is at least three, which are distributed at equal angles and have a working frequency of 20-40kHz.

5. A degreasing agent reactor with self-cleaning function according to claim 1, characterized in that, The optical sensor (14) is a laser triangulation sensor with a measurement accuracy of ±0.1mm.

6. A degreasing agent reactor with self-cleaning function according to claim 1, characterized in that, The nozzle of the annular spray pipe (13) is a rotatable structure, the spray pressure is 2-5MPa, and the spray direction is at an angle of 15°-30° to the inner wall of the spiral hollow material channel (3).

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