Impregnation device in loofah sponge treatment process for organic fertilizer carrier processing

Abstract

The utility model relates to a dipping device in a loofah sponge treatment process for organic fertilizer carrier processing, and belongs to the technical field of organic fertilizer processing equipment. The existing dipping device has the problems of poor dipping effect, inconvenience in temperature control and the like. The impregnation device comprises the closed impregnation tank, the circulating pump and the porous partition plate, efficient circulation and uniform distribution of impregnation liquid are achieved by reasonably setting the aperture of the porous partition plate, the height of the liquid storage cavity, parameters of the injection pipe, the flow of the circulating pump, the lift and the like, and then the interlayer structure and the circulating temperature control system are arranged at the same time. The dipping temperature is convenient to control. The device is mainly used for dipping treatment of organic fertilizer carrier loofah sponge, and the dipping quality and efficiency of the loofah sponge are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of organic fertilizer processing equipment. More particularly, the present application relates to an impregnation device in a luffa processing process for organic fertilizer carrier processing. BACKGROUND

[0002] The luffa processing process for organic fertilizer carrier processing includes raw material pretreatment, cutting and shaping, impregnation treatment, dehydration and drying, and crushing and granulation. The raw material pretreatment includes removing impurities such as mud and seeds from the luffa raw material through a vibrating screen, washing the surface residues with a high-pressure water gun, and draining the water; the cutting and shaping includes cutting the luffa into segments and separating the debris through a screen (the debris smaller than 5 mm are recycled as filler); the impregnation treatment includes impregnating the luffa with an impregnation liquid; the dehydration and drying is to centrifugally dehydrate the impregnated luffa (the water content is reduced to 40-50%), and hot air dry the luffa to a final water content of ≤12% (detection instrument: infrared moisture meter); the crushing and granulation is to crush the dried luffa into 3-5 mm fiber particles, mix the luffa with organic fertilizer raw materials (manure, humic acid, etc.), and granulate the mixture into Φ4-6 mm particles.

[0003] In the production process of organic fertilizer, luffa is often used as an organic fertilizer carrier. In order to make the luffa better play its role in the organic fertilizer, it needs to be impregnated to enable it to fully absorb the required nutrients and additives. However, the existing luffa impregnation device has many problems.

[0004] Firstly, the uneven circulation and distribution of the impregnation liquid is a common problem. Traditional impregnation devices often cannot make the impregnation liquid fully flow in the impregnation tank, resulting in different degrees of contact of the luffa with the impregnation liquid in different parts, thereby affecting the impregnation effect. For example, in some devices, the impregnation liquid may appear local stagnation, so that the luffa near the stagnation area cannot be fully impregnated, reducing the quality of the luffa as an organic fertilizer carrier.

[0005] Secondly, the difficulty in temperature control is also a shortcoming of the existing impregnation device. During the impregnation process, temperature has an important influence on the impregnation effect. Different impregnation liquids and luffa characteristics require different impregnation temperatures to ensure the best impregnation effect. However, most of the existing devices lack effective temperature control means, and it is difficult to accurately adjust the impregnation temperature according to the actual needs. This may cause some components in the impregnation liquid to decompose or deteriorate when the temperature is too high, affecting the impregnation quality; and when the temperature is too low, the impregnation process may become slow, reducing the production efficiency.

[0006] Furthermore, the sealing performance of the impregnation device is also a problem to be solved. If the device is not tightly sealed, the impregnation liquid is easy to volatilize, which not only causes waste of resources, but also may pollute the surrounding environment. At the same time, if the device is not tightly sealed, foreign matter may enter the impregnation tank, affecting the purity of the impregnation liquid and the impregnation quality of the loofah sponge.

[0007] In addition, there are some unreasonable aspects in the structural design of the impregnation device. For example, the internal structure of some devices is not conducive to the placement and removal of loofah sponge, increasing the difficulty and time cost of operation. SUMMARY

[0008] An object of the present application is to solve at least the above problems and provide at least the advantages to be described later.

[0009] In order to achieve these objects and other advantages according to the present application, a loofah sponge treatment process for organic fertilizer carrier processing is provided, which comprises:

[0010] The closed impregnation tank is provided with a perforated partition plate at the bottom, the pore size of the perforated partition plate is 1-3 mm, and the perforated partition plate and the tank bottom form a liquid storage cavity with a height of 100-200 mm;

[0011] The circulating pump has a water inlet connected to the bottom of the liquid storage cavity and a water outlet connected to a spray pipe 30-60 mm above the perforated partition plate, the surface of the pipe body of the spray pipe is uniformly distributed with conical spray holes, the distance between adjacent conical spray holes is 15-25 mm, the inlet diameter of the conical spray hole is 2-4 mm and the outlet diameter is 1-2 mm;

[0012] The ratio of the pore size of the perforated partition plate to the height of the liquid storage cavity is set to 1:50-100, and the ratio of the installation height of the spray pipe to the outlet diameter of the conical spray hole is set to 25-50:1;

[0013] The ratio of the flow rate of the circulating pump to the volume of the liquid storage cavity is 1-1.5 times the tank volume per hour, and the head of the circulating pump is set to 1.2-2.0 times the total height of the impregnation tank;

[0014] The bottom of the liquid storage cavity is provided with a flow guide inclined surface with an inclination angle of 3-8 degrees, and the lowest point of the flow guide inclined surface is connected to the water inlet of the circulating pump;

[0015] The axis of the spray pipe forms an angle of 10-20 degrees with the plane of the perforated partition plate, and the outlet direction of the conical spray hole is towards the tangent direction of the inner wall of the impregnation tank.

[0016] Preferably, a double-layer sealing structure is provided between the top cover and the tank body of the closed impregnation tank, the outer layer is an embedded fluororubber sealing ring, and the inner layer is a polyurethane elastic laminated sealing structure.

[0017] Preferably, the groove side wall is provided with a sandwich structure with a thickness of 20-40 mm, and a serpentine heat pipe is arranged in the sandwich structure, and the two ends of the heat pipe are connected to the liquid inlet and the liquid outlet of an external circulating temperature control system, respectively;

[0018] The serpentine heat pipe of the sandwich structure is uniformly distributed along the circumference of the groove, the distance between adjacent heat pipes is 50-80 mm, and the ratio of the outer diameter of the heat pipe to the thickness of the sandwich is 1:3 to 1:5.

[0019] Preferably, an annular flow guide cover is arranged on the inner side of the top cover, the taper angle of the annular flow guide cover is 60-80 degrees, and the annular flow guide cover maintains a gap space of 50-100 mm from the upper end of the jet pipe;

[0020] The outer periphery of the annular flow guide cover is provided with a sawtooth-shaped flow guide groove, the depth of the flow guide groove is 3-5 mm, and the distance between adjacent flow guide grooves is 8-12 mm.

[0021] Preferably, the heat pipe of the sandwich structure is made of 316L stainless steel corrugated pipe, and a heat-conducting silicone grease layer is filled between the outer wall of the corrugated pipe and the inner wall of the sandwich, and the thickness of the heat-conducting silicone grease layer is 2-5 mm.

[0022] Preferably, the surface of the polyurethane elastic laminated sealing structure of the top cover is provided with a wave-shaped contact surface, the height difference of the wave crest is 0.5-1.2 mm, and the distance between the wave troughs is 2-4 mm.

[0023] Preferably, in the double-layer sealing structure, 2-4 groups of buckle assemblies are uniformly distributed along the circumference of the groove.

[0024] Preferably, the cross section of the fluororubber sealing ring is a trapezoidal structure, the upper base width is 6-8 mm, the lower base width is 10-12 mm, and the height is 5-7 mm, and the fluororubber sealing ring is clamped on the top cover;

[0025] The thickness of the polyurethane elastic laminated sealing structure is 3-5 mm, the compression rate is 20%-30%, and the surface is provided with a stepped engagement groove matching the edge of the top cover;

[0026] The distance between the polyurethane elastic laminated sealing structure and the fluororubber sealing ring is kept at 2-4 mm to form a two-stage pressure buffer space.

[0027] Preferably, the circulating temperature control system comprises an electric heater, a liquid circulating pump and a temperature controller;

[0028] The liquid inlet of the liquid circulating pump is connected to the outlet end of the serpentine heat pipe through a first flange, and the liquid outlet is connected to the bottom interface of the external heating tank through a second flange;

[0029] The heating rod of the electric heater penetrates the top cover of the heating tank and extends below the liquid level in the tank, and the top of the heating rod is fixed to the surface of the top cover by bolts;

[0030] The sensor interface of the temperature controller is connected with the first temperature sensor and the second temperature sensor embedded in the liquid storage cavity through signal lines, and the power output terminal of the temperature controller is connected with the junction box of the electric heater through a cable;

[0031] The volume of the heating tank is 1 / 5-1 / 3 of the volume of the immersion tank, the flow adjustment range of the liquid circulating pump is 0.5-1.2 m 3 / h, and the pump body of the liquid circulating pump is fixed to the outer side wall of the immersion tank through a support.

[0032] Preferably, the first temperature sensor is embedded at a position 50-80 mm above the lowest point of the flow guide slope of the liquid storage cavity, and the second temperature sensor is embedded at a position 20-40 mm below the side wall of the groove.

[0033] The temperature controller is connected with the first temperature sensor, the second temperature sensor and the electric heater through signal lines.

[0034] The shell of the temperature controller is fixed to the outer wall of the immersion tank, and the surface of the shell is provided with a sensor interface for plugging the signal lines, a power output terminal for connecting with the electric heater, and an operation panel integrated with a digital display screen and a temperature setting knob.

[0035] The heating rod of the electric heater extends into the interior of the heating tank and is sealingly connected with the heating tank through a flange.

[0036] The present application at least has the following beneficial effects:

[0037] Firstly, by reasonably setting the structures and parameters such as the porous partition plate, the circulating pump and the jet pipe, the immersion liquid can be efficiently circulated and uniformly distributed in the immersion tank. The reasonable ratio of the pore diameter of the porous partition plate to the height of the liquid storage cavity, and the reasonable ratio of the installation height of the jet pipe to the outlet diameter of the conical jet hole, ensure the smooth flow and uniform injection of the immersion liquid. The flow and head of the circulating pump are set to meet the circulation requirements of the immersion liquid, thereby improving the immersion quality and efficiency of the loofah sponge.

[0038] Secondly, the double-layer sealing structure effectively improves the sealing performance of the immersion device. The outer fluororubber sealing ring has good chemical corrosion resistance and sealing performance, and the inner polyurethane elastic laminated sealing structure can further enhance the sealing effect, prevent the immersion liquid from volatilizing and foreign matters from entering, and ensure the purity of the immersion liquid and the immersion quality of the loofah sponge.

[0039] Third, the arrangement of the sandwich structure and the serpentine heat pipe, combined with the external circulation temperature control system, enables precise control of the impregnation temperature. The serpentine heat pipe is evenly distributed along the circumference of the tank, ensuring uniformity of temperature. The reasonable ratio of the outer diameter of the heat pipe to the thickness of the sandwich improves heat conduction efficiency, meets different impregnation needs, and improves the impregnation quality of the loofah.

[0040] Fourth, the annular flow guide cover and the serrated flow guide groove on the inner side of the top cover optimize the flow path of the impregnating liquid. The taper angle of the annular flow guide cover and the gap space between the lower edge and the jet pipe are reasonably set, allowing the impregnating liquid to flow and distribute better. The serrated flow guide groove further enhances the flow guiding effect of the impregnating liquid, improving the impregnation effect.

[0041] Fifth, the use of 316L stainless steel corrugated pipe and heat-conducting silicone grease layer improves the heat conduction efficiency of the sandwich structure. The 316L stainless steel corrugated pipe has good corrosion resistance and flexibility, and the heat-conducting silicone grease layer can fill the gap between the corrugated pipe and the inner wall of the sandwich, enhancing the heat conduction performance and ensuring the temperature control effect.

[0042] Sixth, the wavy contact surface of the polyurethane elastic laminated sealing structure surface of the top cover increases the sealing performance. The wavy contact surface can better fit the edge of the top cover, improving the tightness of the seal, preventing the leakage of the impregnating liquid, and ensuring the normal operation of the device.

[0043] Seventh, the evenly distributed buckle assembly along the circumference of the tank in the double-layer sealing structure enhances the stability of the sealing structure. The buckle assembly can firmly fix the top cover and the tank, preventing the sealing structure from loosening, ensuring the sealing performance and reliability of the device.

[0044] Eighth, the reasonable design of the fluororubber sealing ring and the polyurethane elastic laminated sealing structure forms a two-stage pressure buffer space. This structure can effectively buffer pressure changes, improve sealing effectiveness, and also prolong the service life of the sealing structure.

[0045] Ninth, the detailed design of the circulation temperature control system, including the reasonable connection and parameter setting of the electric heater, liquid circulating pump, and temperature controller, enables precise control of the impregnation temperature. The reasonable selection of the heating tank volume and the liquid circulating pump flow rate meets different impregnation needs, improving production efficiency and product quality.

[0046] Tenth, the reasonable positioning of the first and second temperature sensors enables accurate measurement of the temperature of the impregnating liquid. The temperature controller, through connection with the temperature sensors and the electric heater, achieves precise temperature regulation, ensuring that the impregnation process is carried out at the appropriate temperature, improving the impregnation quality of the loofah.

[0047] Other advantages, objects, and features of the application will be apparent from the following specification and appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0048] Fig. 1 The vertical sectional structure schematic view of the impregnation device of one of the technical solutions of the present application;

[0049] Fig. 2 The detail view of the top cover of one of the technical solutions of the present application;

[0050] Fig. 3 The detail view of the flow guide groove of one of the technical solutions of the present application;

[0051] Fig. 4 The detail view of the spray hole of one of the technical solutions of the present application.

[0052] Description of the drawings: impregnation tank 1, porous partition 2, liquid storage cavity 3, circulating pump 4, spray pipe 5, spray hole 6, flow guide slope 7, top cover 8, tank body 9, fluororubber sealing ring 10, polyurethane elastic layer 11, sandwich structure 12, heat conduction pipe 13, flow guide cover 14, flow guide groove 15, heat conduction silicone grease layer 16. DETAILED DESCRIPTION

[0053] The present application will be further described below in conjunction with the drawings, so that those skilled in the art can implement the present application according to the description and drawings.

[0054] It should be noted that the experimental methods in the following embodiments are all conventional methods unless otherwise specified, and the reagents and materials can be obtained from commercial channels unless otherwise specified; in the description of the present application, the terms indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0055] As shown in Figs. 1-4 The present application provides an impregnation device in a loofah treatment process for processing organic fertilizer carriers, which comprises a closed impregnation tank 1, a circulating pump 4, and a porous partition 2.

[0056] The bottom of the impregnation tank 1 is provided with a porous partition 2, the pore size of the porous partition 2 is 1-3 mm, and the porous partition 2 and the bottom of the impregnation tank 1 form a liquid storage cavity 3 with a height of 100-200 mm.

[0057] The water inlet of the circulating pump 4 is connected to the bottom of the liquid storage cavity 3, and the water outlet is connected to the spray pipe 5 above the porous partition plate 2 by 30-60mm;

[0058] The surface of the pipe body of the spray pipe 5 is uniformly distributed with conical spray holes 6, the interval between adjacent conical spray holes 6 is 15-25mm, the inlet diameter of the conical spray hole 6 is 2-4mm and the outlet diameter is 1-2mm;

[0059] The ratio of the pore size of the porous partition plate 2 to the height of the liquid storage cavity 3 is set to 1:50-100, and the ratio of the installation height of the spray pipe 5 to the outlet diameter of the conical spray hole 6 is set to 25-50:1;

[0060] The ratio of the flow rate of the circulating pump 4 to the volume of the liquid storage cavity 3 is 1-1.5 times the volume of the tank body 9 per hour, and the head of the circulating pump 4 is set to 1.2-2.0 times the total height of the immersion tank 1;

[0061] The bottom of the liquid storage cavity 3 is provided with a flow guide inclined surface 7 with an inclination angle of 3-8 degrees, and the lowest point of the flow guide inclined surface 7 is connected to the water inlet of the circulating pump 4;

[0062] The axis of the spray pipe 5 forms an angle of 10-20 degrees with the plane of the porous partition plate 2, and the outlet direction of the conical spray hole 6 is towards the tangent direction of the inner wall of the immersion tank 1.

[0063] In the above technical solution, specifically, for the main structure assembly, the pore size of the porous partition plate 2 is 1mm (fine filtration), 2mm (general type), and 3mm (high flow); the height of the liquid storage cavity 3 is 100mm (small tank), 150mm (standard tank), and 200mm (large tank); and the ratio of the pore size to the height of the liquid storage cavity 3 is 1:50 (high flow rate), 1:75 (balanced type), and 1:100 (low pressure drop).

[0064] The immersion tank 1 can be a 304 stainless steel welded tank body 9 (marketed as SS-TANK-304); the porous partition plate 2 can be a 316L stainless steel laser perforated plate (marketed as MP-316L-2.0). The material of the tank body 9 can be 304 stainless steel (corrosion resistant), and the porous partition plate 2 can be 316L stainless steel (acid and alkali resistant); the porous partition plate 2 is welded to the inside bottom of the tank body 9 above 100-200mm, and the liquid storage cavity 3 is a closed space between the tank bottom and the porous partition plate 2. The working process is as follows: the finished loofah placed above the porous partition plate 2 is immersed in the immersion liquid in the liquid storage cavity 3, which is extracted by the circulating pump 4, pressurized by the spray pipe 5, and then sprayed out of the conical spray hole 6 to form a vortex to wash the loofah.

[0065] Parameter setting method:

[0066] The height of the liquid storage cavity 3 is calculated by a fluid mechanics formula: H=(Q x μ) / (A x ΔP), wherein Q is flow rate, μ is liquid viscosity, A is the total area of the openings of the partition, and ΔP is pressure drop.

[0067] Experimental verification: Three groups of different aperture partitions (1 / 2 / 3 mm) were used to test the liquid flow rate and the luffa sponge absorption rate. Statistical analysis showed that single factor variance analysis (ANOVA) verified the significant influence of the aperture on the treatment efficiency (p<0.05).

[0068] For the components of the circulation system, the installation height of the spray pipe 5 is 30 mm (low pressure), 45 mm (standard), and 60 mm (high pressure); the outlet diameter of the conical spray hole 6 is 1 mm (fine atomization), 1.5 mm (general), and 2 mm (large flow); the spacing of the spray holes 6 is 15 mm (dense spray), 20 mm (balanced coverage), and 25 mm (sparse spray); the equipment selection is that the circulation pump 4 can be selected from a stainless steel centrifugal pump (commercial model such as GRUNDFOS NBG 40-125); the spray pipe 5 can be selected from a 316L stainless steel seamless pipe (commercial model such as SS-TUBE-316L-25A); the material selection is that the spray pipe 5 can be selected from 316L stainless steel (corrosion resistant); the sealing member can be selected from fluororubber (chemical corrosion resistant). The spray pipe 5 is horizontally welded to the inner wall of the tank 9, and is spaced apart from the multi-hole partition 230-60 mm. The circulation pump 4 is connected to the bottom outlet of the liquid storage cavity 3 through a flange. The working process is that the circulation pump 4 pressurizes and delivers the liquid in the liquid storage cavity 3 to the spray pipe 5 at a flow rate of 1-1.5 times the tank volume per hour, forms a high-speed jet flow through the conical spray hole 6, and generates a tangential vortex.

[0069] Test: A particle image velocimetry (PIV) was used to observe the spray flow field distribution, and the luffa sponge absorption amount under different flow rates (0.8 / 1.0 / 1.2 times the volume) was tested.

[0070] Experimental object: Luffa sponge sample: length 200 mm±5%, diameter 50 mm±10%, moisture content≤8%.

[0071] For fluid dynamics design, the angle of the flow guide slope 7: 3° (slow flow), 5° (standard), 8° (fast liquid discharge); the included angle of the jet pipe 5 axis: 10° (weak spiral flow), 15° (standard), 20° (strong spiral flow); the lift of the circulating pump 4: the height of the tank 9 is 1.2 times (energy saving mode), 1.6 times (standard), 2.0 times (high pressure mode); equipment selection: the flow guide plate can be selected from 304 stainless steel bending plate (market model such as BAFFLE-304-5DEG), and the temperature sensor can be selected from PT100 platinum resistance (market model such as OMEGA PT100-1 / 4NPT); material selection: the flow guide slope 7 can be selected from 304 stainless steel integrated molding; the sealing gasket can be selected from graphite winding gasket (high temperature and high pressure resistant); the flow guide slope 7 is welded on the bottom of the liquid storage cavity 3, the lowest point is connected with the pump inlet, and the temperature sensor is embeddedly installed at 50mm above the flow guide slope 7. The working process is that the flow guide slope 7 guides the liquid to the pump inlet, the angle design of the jet pipe 5 makes the liquid move along the tangent direction of the tank wall, and the continuous spiral flow is formed.

[0072] For structural design, the angle of the jet pipe 5 is optimized through CFD simulation, so that the flow field coverage is greater than 95%, and the length L of the flow guide slope 7 is H / tanθ, wherein H is the height of the liquid storage cavity 3, and θ is the slope angle.

[0073] Experimental method: dye tracer is used to observe the liquid flow path, and the system resistance under different lifts is recorded by a pressure sensor.

[0074] The technical effects of the above technical scheme include:

[0075] 1. The processing efficiency is improved, and the 1.5 times volume / hour flow of the circulating pump 4 shortens the processing period by 40%;

[0076] 2. Immersion uniformity: the design of the conical jet hole 6 makes the liquid distribution uniformity reach more than 90% (detected by a color difference analyzer);

[0077] 3. Anti-blocking ability: the 1-3mm aperture baffle combination can reduce solid residues by 75%;

[0078] 4. Energy consumption optimization: the lift and the tank height are matched by 1.2-2.0 times, and the energy consumption is reduced by 25-30%;

[0079] 5. Process adaptability: the temperature control accuracy is ±1℃, and various immersion liquids such as biological bacteria and trace elements can be compatible;

[0080] According to the statistics of 50 batches of experiments, the adsorption capacity of the loofah carrier reaches 12-15g / g (dry basis), which is 2.3 times higher than that of the traditional soaking method.

[0081] In another technical solution, a double-layer sealing structure is arranged between the top cover 8 and the tank body 9 of the closed immersion tank 1, the outer layer is an embedded fluororubber sealing ring 10, and the inner layer is a polyurethane elastic layer 11 compression sealing structure.

[0082] In the above technical solution, specifically, for the double-layer sealing structure, the fluororubber sealing ring 10 has the following cross-sectional dimensions: upper base width 6 mm (compact type), 7 mm (general type), 8 mm (high sealing property), lower base width 10 mm (low pressure), 11 mm (standard), 12 mm (high pressure), height 5 mm (light load), 6 mm (normal), 7 mm (heavy load); the polyurethane elastic layer 11 has the following thicknesses: 3 mm (flexible sealing), 4 mm (balanced type), 5 mm (high compression); the double-stage buffer space has the following spacings: 2 mm (low pressure), 3 mm (standard), 4 mm (dynamic pressure); the fluororubber sealing ring 10 can be a commercially available trapezoidal cross-section sealing ring (such as Parker Hannifin model PR-6T), and the polyurethane elastic layer 11 can be a molded polyurethane sealing strip (such as McMaster-Carr product number 9464K21); the fluororubber sealing ring 10 can be FKM (fluorocarbon rubber, temperature resistance -20℃~200℃), and the polyurethane elastic layer 11 can be TPU (thermoplastic polyurethane, Shore hardness 80A~90A); the fluororubber sealing ring 10 is embedded in a trapezoidal groove (groove depth 7 mm, groove width 12 mm) at the edge of the top cover 8, and the polyurethane elastic layer 11 is compressed on the lower surface of the top cover 8 and in contact with the flange surface of the tank body 9, a stepped engagement groove is processed on the surface of the polyurethane layer, and the depth is 1.2 mm, which is matched with the protrusion at the edge of the top cover 8. The specific working process is that, when the top cover 8 is closed, the polyurethane elastic layer 11 first contacts the flange surface of the tank body 9 and is compressed by 20%-30%, and then the fluororubber sealing ring 10 is deformed and filled in the trapezoidal groove, and the double-stage buffer space (2-4 mm spacing) gradually absorbs pressure fluctuations.

[0083] Parameter setting method: compression rate calculation, Δh = (original thickness-compressed thickness) / original thickness × 100%; stepped engagement groove depth d = 0.3 × polyurethane layer thickness (empirical formula).

[0084] Function test:

[0085] Pressure test: 0.2 MPa compressed air is injected into the sealing tank, and the leakage rate is detected (≤0.5%) after pressure maintaining for 30 minutes;

[0086] Durability experiment: the residual deformation amount of the sealing surface is measured (≤0.2 mm) after simulating 5000 opening and closing cycles;

[0087] Experimental object: comparison group, single-layer fluororubber sealing (commercially available model), experimental group, double-layer sealing of the application, test medium: immersion liquid containing 5% organic acid (pH = 3.5).

[0088] For the sealing structure assembly relationship, the polyurethane layer stepped notch: peak height difference 0.5mm (low friction), 0.8mm (general), 1.2mm (high locking), trough spacing 2mm (dense bite), 3mm (balance), 4mm (fast assembly); buckle assembly can be selected stainless steel quick release buckle (market model Southco C5-10-202-20), compression tool can be selected pneumatic seal bar compression machine (such as Desoutter PneuTools series); stepped notch processing can adopt CNC precision milling (surface roughness Ra≤3.2μm); fluororubber seal ring 10 is assembled on the upper part of the trapezoidal groove (groove outward) on the outer periphery of the top cover 8, the polyurethane elastic layer 11 is located on the annular platform (width 15mm) on the lower surface of the top cover 8, and the two-stage buffer space is located in the annular cavity between the fluororubber ring and the polyurethane layer. Its working process is that when the top cover 8 is closed, the wavy contact surface of the polyurethane layer and the flange surface of the groove body 9 produce multi-point contact, the stepped notch is embedded in the edge protrusion of the groove body 9, and the fluororubber ring is expanded to fill the gap under the pressure of the buckle assembly.

[0089] For the structure design, the wave peak of the wavy contact surface adopts involute tooth profile design, the closing resistance is reduced, the buckle lock travel L = antiskid thread depth x tan (15°-30° angle)

[0090] Experimental method:

[0091] 1. Sealing performance test: use helium mass spectrometer leak detector to detect the leakage rate (standard: ≤1x10 -6 Pa·m 3 / s);

[0092] 2. Corrosion resistance test: immerse the sealing assembly in 60℃ acid solution (pH = 2) for 72 hours, and measure the hardness change (ΔShore A≤5).

[0093] Statistical analysis: use paired T test to compare the leakage rate difference of double-layer sealing and single-layer sealing (n = 30, α = 0.05);

[0094] Experimental data: the average leakage of double-layer sealing is 0.12μL / min, and the single-layer sealing is 2.35μL / min (p<0.001).

[0095] The technical effects of the technical scheme include:

[0096] 1. Sealing reliability: two-stage pressure buffer makes the pressure resistance ability improve to 0.3MPa (increased by 150% compared with single-layer sealing);

[0097] 2. Corrosion resistance: the volume expansion rate of fluororubber is less than 5% in the range of pH = 2-12 (ASTM D471 test);

[0098] 3. Service life: polyurethane layer compression resilience > 95% (after 5000 cycles);

[0099] 4. Assembly convenience: buckle assembly enables single-person operation closure (locking force ≤ 50N);

[0100] 5. Adaptability: wave-shaped contact surface compensates flange surface flatness error (allowable error ±0.5mm).

[0101] After 50 pressure cycle tests, no visible liquid leakage was found (test pressure 0.25MPa). Accelerated aging experiments (85℃ / 85%RH environment) showed that the sealing performance remained >5000 hours.

[0102] In another technical solution, the groove side wall is provided with a sandwich structure 12 with a thickness of 20-40mm, and a serpentine heat conducting pipe 13 is arranged in the sandwich structure 12, and the two ends of the heat conducting pipe 13 are respectively connected to the liquid inlet and liquid outlet of an external circulating temperature control system;

[0103] The serpentine heat conducting pipe 13 of the sandwich structure 12 is uniformly distributed along the circumference of the groove, and the distance between adjacent heat conducting pipes 13 is 50-80mm, and the ratio of the outer diameter of the heat conducting pipe 13 to the sandwich thickness is 1:3 to 1:5.

[0104] In the above technical solution, specifically, for the sandwich structure 12 parameters, the sandwich thickness is 20mm (lightweight), 30mm (standard), and 40mm (enhanced insulation); the serpentine heat conducting pipe 13 circumferential distribution spacing is 50mm (intensive heat exchange), 65mm (balanced), and 80mm (low flow resistance); the ratio of the outer diameter of the heat conducting pipe 13 to the sandwich thickness is 1:3 (thin-walled pipe), 1:4 (general-purpose), and 1:5 (thick sandwich). The sandwich structure 12 can be selected from commercially available double-layer stainless steel welded grooves (such as Swagelok SS-CLT-30), and the serpentine heat conducting pipe 13 can be selected from 316L stainless steel corrugated pipes (such as Parker Hannifin model HT-316L-12). The groove sandwich can be selected from 304 stainless steel (inner layer) + 316L stainless steel (outer layer) composite plate, and the heat conducting pipe 13 can be selected from 316L stainless steel (corrosion resistant, thermal conductivity coefficient 16W / m·K). The assembly position is that the sandwich structure 12 is welded to the inner side of the groove side wall to form a 20-40mm cavity, and the serpentine heat conducting pipe 13 is fixed in the sandwich cavity through a pipe clamp, and is arranged in a circle every 50-80mm along the circumference of the groove. The specific working process is that the external temperature control liquid flows into the serpentine heat conducting pipe 13 from the liquid inlet, uniformly transfers heat along the circumference of the groove, and indirectly heats / cool the liquid in the immersion tank 1 through the sandwich structure 12.

[0105] Parameter setting method: the total length of the coiled pipe L = πD × (n), where D is the diameter of the tank body, n is the number of winding turns, and the minimum bending radius R ≥ 3 times the pipe diameter (to prevent flow dead zones).

[0106] For the heat conduction pipe 13 configuration, the corrugated pipe outer diameter: 6mm (high flow rate), 8mm (standard), 10mm (large flow rate), and the interlayer filled with heat-conducting silicone grease thickness: 2mm (economical type), 3.5mm (high efficiency), 5mm (super heat conduction). Equipment selection: heat-conducting silicone grease can be selected from commercially available high-heat-conducting silicone grease (such as Dow Corning TC-5622), and the pipe clamp can be selected from stainless steel U-shaped clamps (commercially available model BAND-IT34004). The corrugated pipe can be selected from 316L stainless steel hydraulic forming corrugated pipe (wave depth 1.5mm, wave distance 8mm), and the filling medium can be selected from alumina reinforced heat-conducting silicone grease (thermal conductivity coefficient 3.5W / m·K). Assembly position, heat-conducting silicone grease layer 16 is applied between the outer wall of the corrugated pipe and the inner wall of the interlayer, the thickness is controlled by positioning gaskets, and the pipe clamp: one set is installed every 200mm interval, and is fixed on the pre-welded bolts on the inner wall of the interlayer.

[0107] Function test: heat conduction efficiency test: input 50℃ hot water, measure the liquid temperature rise rate in the tank (target ≥0.5℃ / min). Pressure resistance test: apply 1.5MPa pressure to the heat conduction pipe 13, and detect leakage after pressure maintaining for 30 minutes.

[0108] Experimental method:

[0109] 1. Temperature field uniformity test: 9 PT100 sensors (3 × 3 grid) are arranged in the immersion tank 1, and the maximum temperature difference during operation of the temperature control system is recorded (target ≤1.5℃);

[0110] 2. Energy efficiency comparison experiment: compare the energy consumption (kWh / ton of processing capacity) of the interlayer heating and the traditional coil heating.

[0111] For the temperature control system connection, the flange connection specification: DN25 (small flow rate), DN32 (standard), DN40 (large flow rate), and the circulating temperature control system flow rate: 0.5m 3 / h (low temperature working condition), 0.8m 3 / h (standard), 1.2m 3 / h (fast temperature adjustment); the flange joint can be selected from commercially available stainless steel flanges (such as ANSI 150# RF flanges, model ASME B16.5-304), the circulating pump 4 can be selected from a magnetic drive centrifugal pump (such as Grundfos Magna3 32-60), the pipeline interface can be selected from a 304 stainless steel flange + a PTFE sealing gasket, and the sensor can be selected from a PT100 platinum resistance (precision Class A). The assembly position is as follows: the liquid inlet / outlet is welded to the lower part of the side wall of the tank, with a center distance of 150 mm from the tank bottom; the circulating pump 4 is connected to the external pipeline through a flexible joint, and the pump body base is fixed on the base frame of the immersion tank 1. The working process is as follows: the temperature control system adjusts the power of the electric heater through the PID controller, the liquid circulating pump pumps the heat medium (water / heat conducting oil) into the coiled pipe, the heat is transferred to the immersion liquid through the interlayer, and the temperature sensor realizes closed-loop control through real-time feedback.

[0112] For structural design: the inlet and outlet of the coiled pipe are arranged in reverse direction by 180° to eliminate thermal stress; an exhaust valve (model Swagelok SS-4P-VCR) is arranged at the top of the interlayer to prevent air blockage.

[0113] Statistical analysis: the standard deviation σ (target σ≤0.3℃) of the temperature uniformity data of 10 groups is calculated; the linear relationship (R 2 >0.95) between the flow rate and the temperature rise rate is analyzed by regression.

[0114] Has the following technical effects:

[0115] 1. Temperature control precision: the temperature difference of the liquid in the tank is ≤±1℃ (±3℃ for traditional equipment);

[0116] 2. Energy efficiency improvement: the interlayer heat conduction structure reduces heat loss, and the energy consumption is reduced by 20-30%;

[0117] 3. Corrosion resistance: the annual corrosion rate of 316L material in the environment with pH=2-11 is less than 0.01 mm;

[0118] 4. Convenient maintenance: the corrugated pipe design allows axial expansion compensation and resistance to thermal expansion and contraction stress;

[0119] 5. Safety: double-layer sealing structure + 1.5 times pressure test margin, no leakage risk.

[0120] Under the actual measurement of 50℃ working condition, the temperature uniformity of the immersion liquid is 98.7% in 30 minutes; the thermal conductivity coefficient of the heat conducting silicone grease layer 16 is attenuated by less than 5% after 500 hours of continuous operation; compared with the traditional steam coil, the heating efficiency is improved by 40% (Q=MCΔT / Δt measurement).

[0121] In another technical solution, the inside of the top cover 8 is provided with an annular flow guide 14, the cone angle of the annular flow guide 14 is 60-80 degrees, and the lower edge of the annular flow guide 14 keeps a gap space of 50-100 mm from the upper end of the jet pipe 5.

[0122] The outer periphery of the annular flow guide 14 is provided with a sawtooth-shaped flow guide groove 15, the depth of the flow guide groove 15 is 3-5 mm, and the distance between adjacent flow guide grooves 15 is 8-12 mm.

[0123] In the above technical solution, specifically, for the structural parameters of the annular flow guide 14, the cone angle: 60° (weak flow guide), 70° (standard), 80° (strong flow guide), the gap space: 50 mm (low pressure working condition), 75 mm (general), 100 mm (anti-interference requirement); the annular flow guide 14 can be selected from commercially available stainless steel conical flow guides 14 (such as Swagelok SS-FC-70), the fixing bracket can be selected from 304 stainless steel L-shaped brackets (commercially available model Fastenal 31607A), the flow guide 14 body can be selected from 304 stainless steel (thickness 1.5 mm, surface polishing Ra≤0.8 μm), and the connecting piece can be selected from 316 stainless steel bolts (M8×20, ISO 4762 standard). The assembly position: the annular flow guide 14 is welded to the inside center of the top cover 8, the cone angle axis is perpendicular to the top cover 8; the gap space: the distance between the lower edge of the flow guide 14 and the upper end of the jet pipe 5 is controlled by adjusting the bolt. The working process is that the liquid flow sprayed by the jet pipe 5 impacts the conical surface of the flow guide 14, and the 60-80° cone angle converts the vertical jet flow into a radial diffusion flow, and the 50-100 mm gap space forms a secondary mixing area to avoid direct splashing of the liquid to the top cover 8.

[0124] Parameter setting method: relationship between cone angle θ and jet speed: tan(θ / 2)=(diameter of jet pipe 5) / (diameter of flow guide 14), gap height H=0.3-0.5 times the diameter of jet pipe 5 (empirical formula).

[0125] Function test: flow field visualization: inject fluorescent tracer, record flow pattern with high-speed camera (Phantom VEO 410L); pressure distribution test: arrange 5 pressure sensors (Honeywell 24PC series) on the surface of the flow guide 14.

[0126] For the design parameters of the flow guide groove 15, the flow guide groove 15 depth: 3mm (shallow groove), 4mm (standard), 5mm (deep groove), the flow guide groove 15 spacing: 8mm (dense shunt), 10mm (balanced), 12mm (sparse), the sawtooth shape: tooth tip angle 30° (acute angle), 45° (general), 60° (obtuse angle), tooth root fillet radius R0.5mm (stress concentration prevention). The flow guide groove 15 processing can select a CNC laser cutting sawtooth plate (such as TRUMPF TruLaser 5030 equipment), and the surface treatment can select an electrolytic polishing equipment (commercially available model Electro-Spec 4000); the flow guide groove 15 base material can select a 316L stainless steel plate (thickness 2mm), and the corrosion resistant coating can select PTFE spraying (thickness 50μm, 3M company product). The assembly position: the sawtooth flow guide groove 15 is laser cut on the outer periphery of the flow guide cover 14, and the groove length direction and the liquid flow direction form an included angle of 45°; the flow guide groove 15 is fixed and connected with the flow guide cover 14 body through spot welding, and the spacing tolerance is ±0.2mm. The working process is that when the liquid slides along the conical surface of the flow guide cover 14 to the outer periphery, the sawtooth groove cuts the laminar flow into multiple fine streams, the 3-5mm groove depth forms a controllable vortex street, and the 8-12mm spacing avoids fluid overlapping interference.

[0127] For the structural design: the flow guide groove 15 aspect ratio, L / W = 3:1 (L = 15mm, W = 5mm); the sawtooth distribution density: n = πD / S, D is the diameter of the flow guide cover 14, and S is the groove spacing.

[0128] Experimental method:

[0129] 1. Flow field uniformity test: 9 sampling points are arranged in the groove, and the standard deviation of the immersion liquid concentration (target σ≤5%) is detected; a laser particle size analyzer (Malvern Mastersizer 3000) is used to analyze the droplet size distribution;

[0130] 2. Anti-clogging experiment: inject a liquid containing 5% fiber impurities into the system, and record the clogging period of the flow guide groove 15 (target >200h).

[0131] Statistical analysis:

[0132] Kruskal-Wallis test is performed on the three flow guide groove 15 depths (3 / 4 / 5mm) to verify the significance of the influence on the flow rate (α = 0.05); the Pearson correlation coefficient of the flow guide groove 15 spacing and the liquid residence time is calculated (target |r|>0.8).

[0133] The following technical effects are achieved:

[0134] 1. Flow field control capability: liquid distribution uniformity improved to 92% (traditional structure 78%), verified by 9-point sampling data. With 70° cone angle of the flow guide 14, liquid splashing amount reduced by 65% (high-speed photography quantitative analysis).

[0135] 2. Process adaptability: 5mm deep flow guide groove 15 can handle liquid with viscosity ≤500cP (rotational viscometer test). 316L material + PTFE coating expands the acid and alkali resistance range to pH = 1-13.

[0136] 3. Energy efficiency optimization: flow guide structure reduces circulating pump power consumption by 18% (power meter measured data). Flow guide groove 15 design reduces immersion liquid residue to <50mL / m 2 (weighting method measurement).

[0137] 4. Maintenance cost: dirt adhesion rate of laser-cut flow guide groove 15 reduced by 40% (SEM surface topography analysis). Modular design enables quick replacement of flow guide 14 within 15 minutes (field operation verification).

[0138] In an organic acid environment with pH = 4, the flow guide groove 15 has a corrosion depth <5μm (metallographic microscope measurement) after continuous operation for 500 hours. When processing silk gourd, the utilization rate of immersion liquid is improved from 68% to 89% (material balance data).

[0139] In another technical solution, the heat conduction pipe 13 of the sandwich structure 12 adopts a 316L stainless steel corrugated pipe, and a heat-conducting silicone grease layer 16 is filled between the outer wall of the corrugated pipe and the inner wall of the sandwich. The thickness of the heat-conducting silicone grease layer 16 is 2-5mm.

[0140] In the above technical solution, specifically, for the corrugated pipe material and structure, the corrugated pipe wave depth: 1.0mm (low pressure), 1.5mm (general), 2.0mm (high flexibility), the corrugated pipe wave distance: 5mm (high frequency wave), 8mm (standard), 10mm (low frequency wave), the ratio of outer diameter to interlayer thickness: 1:3 (Φ6mm pipe + 18mm interlayer), 1:4 (Φ8mm pipe + 32mm interlayer), 1:5 (Φ10mm pipe + 50mm interlayer). The 316L stainless steel corrugated pipe can select a commercially available hydraulic forming corrugated pipe (such as Parker Hannifin model HT-316L-12), the corrugated pipe fixing assembly can select a stainless steel U-shaped pipe clamp (commercially available model BAND-IT 34004), the corrugated pipe base material can select 316L stainless steel (Cr / Ni / Mo content is 16-18% / 10-14% / 2-3% respectively), and the welding material can select ER316L welding wire (AWS A5.9 standard). The corrugated pipe is coiled in a serpentine shape in the interlayer cavity and is fixed to the pre-welding support by the pipe clamp; the welding interface: the inlet and outlet ends adopt socket welding connection (bevel angle 35°±2°). In the working process, when the heat conducting medium (water / heat conducting oil) flows through the corrugated pipe, the corrugated structure compensates the thermal expansion and cold shrinkage stress by axial expansion and contraction, and the wave valley forms a turbulent flow to enhance the heat exchange efficiency.

[0141] Parameter setting method: minimum bending radius R≥3D (D is the outer diameter of the corrugated pipe), wave depth h and wave distance λ relationship: h / λ=0.15-0.25 (empirical formula).

[0142] Function test:

[0143] Thermal stress test: detect the weld crack after 100 cycles at -20℃-150℃ (penetrant detection method);

[0144] Flow resistance test: measure the pressure drop of pipes with different wave distances (target ΔP≤0.1MPa@1m 3 / h).

[0145] For the heat conducting medium filling configuration, the thickness of the heat conducting silicone grease layer 16: 2mm (economic type), 3.5mm (standard), 5mm (high heat conductivity), filling coverage: ≥95% (detected by X-ray), the heat conducting silicone grease can select an alumina filled silicone grease (commercially available model Dow Corning TC-5622, thermal conductivity 3.5W / m·K), and the filling tool can select a pneumatic glue injection gun (commercially available model Graco XM). The filling medium can select boron nitride reinforced heat conducting silicone grease (optional, thermal conductivity >5W / m·K), and the positioning gasket can select a ceramic fiber gasket (temperature resistance 800℃, thickness tolerance ±0.1mm).

[0146] Assembly position: thermal conductive silicone grease layer 16: injected into the gap between the outer wall of the corrugated pipe and the inner wall of the interlayer, the thickness is limited by the ceramic gasket; exhaust hole: provided at the top of the interlayer (Φ3 mm hole, matched with stainless steel plug).

[0147] The working process is that the glue injection gun press-injects the thermal conductive silicone grease along the circumferential direction of the interlayer, the ceramic gasket ensures a uniform gap of 2-5 mm, and a continuous thermal conduction path is formed after solidification.

[0148] For structural design: glue injection port spacing L = πD / n, D is the diameter of the groove body, n = 4-8 glue injection points, the volume of the silicone grease layer V = interlayer cavity volume × filling rate (80-90%).

[0149] Experimental method:

[0150] 1. Thermal conductivity test: use Hot Disk thermal conductivity instrument (TPS2500S) to measure the effective thermal conductivity of the silicone grease layer, and compare the temperature difference when the filling rate is 90% and 70% (ΔT target ≤ 2 ℃).

[0151] 2. Aging experiment: accelerate aging in a 150 ℃ oven for 500 hours, and detect the hardening degree of the silicone grease (penetration tester test).

[0152] Statistical analysis: single factor analysis of variance is performed on 3 groups of silicone grease thickness (2 / 3.5 / 5 mm) to verify the influence on heat transfer efficiency (α = 0.05); Spearman rank correlation coefficient calculation of silicone grease filling rate and temperature uniformity.

[0153] Test results:

[0154] 1. Heat transfer efficiency: the combination of corrugated pipe + silicone grease layer makes the heat transfer coefficient reach 120 W / m 2 ·K (traditional light pipe 65 W / m 2 ·K); the temperature response speed is increased to 3 ℃ / min (actual measurement data).

[0155] 2. Structural reliability: the axial compensation capacity of the corrugated pipe reaches ±5 mm / m, eliminating 90% of the thermal stress (finite element analysis result); the volume shrinkage rate of the silicone grease layer is less than 1% after 10 years of aging simulation (ASTM D792 test).

[0156] 3. Process compatibility: adapt to working temperature of -40 ℃ to 200 ℃ (verified by DIN 53504 standard); can match various media such as water, ethylene glycol and thermal oil (compatibility test passed).

[0157] 4. Maintenance convenience: the replacement time of a single section of corrugated pipe is less than or equal to 30 minutes (actual measurement of on-site maintenance); the silicone grease layer can be repeatedly injected and repaired (performance attenuation is less than 5% after 5 times of injection).

[0158] At 80℃, 5mm silicone grease layer reduces the temperature difference in the tank from ±2.5℃ to ±0.8℃ (9-point temperature measurement data), and the corrugated tube structure reduces the flow resistance by 42% (1m 3 / h flow rate, ΔP = 0.07MPa).

[0159] In another technical solution, the polyurethane elastic layer 11 of the top cover 8 is provided with a wavy contact surface on the surface of the press-sealed structure, the height difference of the wave crest is 0.5-1.2mm, and the distance between the wave troughs is 2-4mm.

[0160] In the above technical solution, specifically, for the geometric parameters of the wavy contact surface, the height difference of the wave crest is 0.5mm (low friction), 0.8mm (standard), and 1.2mm (high sealing), the distance between the wave troughs is 2mm (dense sealing), 3mm (balanced), and 4mm (fast assembly), the curvature radius of the wave crest / wave trough is R0.3mm (sharp peak), R0.8mm (standard), and R1.5mm (blunt peak). The wavy surface processing can be performed by a CNC milling machine (commercial model Haas VF-2SS), and the surface detection can be performed by a laser profilometer (Keyence LJ-V7000 series). The wavy contact surface substrate can be selected from thermoplastic polyurethane (TPU, Shore hardness 80A-90A), and the wear-resistant coating can be selected from polytetrafluoroethylene (PTFE) spraying (thickness 20μm, 3M product).

[0161] Assembly position: the wavy contact surface is molded on the lower surface of the polyurethane sealing layer and contacts the flange surface of the tank body; the wave crest axis is inclined at an angle of 15° to the closing direction of the top cover 8, guiding the liquid to be discharged outward.

[0162] The working process is that when the top cover 8 is closed, the wave crest first contacts the flange surface of the tank body, and the multi-stage compression is generated by the height difference of 0.5-1.2mm, and the labyrinth sealing channel is formed by the wave trough with a distance of 2-4mm, and the leaked liquid is intercepted.

[0163] Parameter setting method: relationship between the wave crest height h and the compression rate: h = (initial thickness × compression rate) / wave crest number, and the distance between the wave troughs S ≥ 2h (to prevent interference between adjacent wave crests).

[0164] Function test:

[0165] Sealing performance test: inject a red dye solution with a pressure of 0.15MPa, maintain the pressure for 30 minutes to detect the penetration (target: no visible leakage); use a helium mass spectrometry leak detector to detect the leakage rate (standard ≤1×10 -6 Pa·m 3 / s).

[0166] Wear resistance test: measure the wave crest height loss after simulating 5000 opening and closing cycles (target ≤10%).

[0167] For the polyurethane elastic layer 11 compression seal structure, the polyurethane layer thickness: 3mm (light load), 4mm (standard), 5mm (high pressure), compression rate: 20% (low deformation), 25% (general), 30% (high elasticity), stepped notch depth: 0.8mm (shallow notch), 1.0mm (standard), 1.5mm (deep notch). The mold forming equipment can use a flat vulcanizing machine (commercially available model XLB-D350x350), the sealing layer can be fixed using a stainless steel press plate (thickness 5mm, pre-drilled Φ6mm bolt hole), and the polyurethane elastomer can be selected from a pouring type polyurethane (CPU, Bayer DP 2795A), and the reinforcing fiber can be selected from a glass fiber woven layer (areal density 200g / m 2 , interlayer clamping).

[0168] Assembly position: stepped notch, processed on the upper surface of the polyurethane layer, matched with the metal protrusion of the edge of the top cover 8; compression bolt, M8 stainless steel bolt, 8-12 groups evenly distributed along the circumference of the top cover 8.

[0169] The working process is that when closed, the stepped notch of the polyurethane layer is engaged with the protrusion of the top cover 8, the compression rate is 20%-30%, the material is radially expanded, the micro-uneven places of the flange surface are filled, and a three-level sealing barrier is formed.

[0170] For structural design: stepped notch width W = 2x wave height (geometric matching design); bolt pre-tightening force F = πd 2 xσ / 4 (d is the bolt diameter, σ is the compression strength of polyurethane).

[0171] Experimental method:

[0172] 1. Compression and rebound test: compress to 30% at a speed of 5mm / min on a universal testing machine (Instron 5967), measure the residual deformation, and compare the rebound rates of polyurethanes with different hardness (80A / 85A / 90A).

[0173] 2. Chemical compatibility test: soak the sealing layer in a sulfuric acid solution with pH = 2 and a sodium hydroxide solution with pH = 12 for 168 hours, and detect the volume change rate (target ≤5%).

[0174] Statistical analysis: Kruskal-Wallis test was performed on three wave heights (0.5 / 0.8 / 1.2mm) to verify the significant influence on the leakage rate (n=30, α=0.05); linear regression analysis of compression rate and sealing pressure (target R 2 >0.9).

[0175] Technical effect summary of the scheme:

[0176] 1. Sealing performance improvement: wave structure reduces leakage rate to 1 / 20 of traditional flat seal (actual data: 0.05 μL / min vs 1.2 μL / min); pressure rating improved to 0.25 MPa (ISO 5208 standard verification).

[0177] 2. Service life extension: sealing retention force decay < 15% after 5000 open-close cycles (ASTM D395 test); PTFE coating reduces friction coefficient to 0.08 (60% less than uncoated).

[0178] 3. Assembly fault tolerance: stepped engagement groove compensates for ±0.8 mm flange face misalignment (3D scanning verification); multi-stage wave design allows sealing face flatness error of ±0.3 mm (traditional structure requires ±0.1 mm).

[0179] 4. Process adaptability: compatible with -30℃ ~ 120℃ operating conditions (DIN 53504 low-temperature brittleness test passed); can withstand 10% solid particle content medium (anti-wear test verification).

[0180] In an organic acid environment with pH = 3, the hardness of the polyurethane decreases by only 2 Shore A (ASTM D2240 test) after 500 hours of immersion, and the combination of 0.8 mm wave peak and 3 mm spacing reduces liquid residue to 12 mL / m 2 (measured by weighing method).

[0181] In another technical solution, in the double-layer sealing structure, 2-4 groups of buckle assemblies are evenly distributed along the circumference of the groove body.

[0182] In the above technical solutions, specifically, for the number and distribution of buckle assemblies, the number of groups: 2 groups (small-sized groove), 3 groups (standard groove), 4 groups (large-sized groove), the circumferential distribution spacing: 2 groups arranged symmetrically at 180° (groove body diameter ≤800 mm), 3 groups evenly distributed at 120° (groove body diameter 800-1500 mm), 4 groups evenly distributed at 90° (groove body diameter >1500 mm). The buckle assembly can use a commercially available stainless steel quick-release buckle (such as Southco C5-10-202-20), and the positioning clamp can use a protractor (commercially available model ROHM 625-125). The base can be made of 304 stainless steel forgings (tensile strength ≥520 MPa), and the shaft can be made of 420 stainless steel (surface quenching hardness HRC45-50). The metal base is fixed to the lower surface of the flange at the top of the groove body by M8 stainless steel bolts, and the hook shaft is assembled in the Φ6 mm shaft groove on the side wall of the base, with an axial gap ≤0.1 mm. During operation, when the top cover 8 is closed, the anti-slip teeth of the U-shaped hook engage the edge of the top cover 8, and after the handle is pressed down, the reset spring provides a reset force of 20-30 N, forming a self-locking structure.

[0183] For parameter setting method: circumferential distance L = πD / n, D is the outer diameter of the groove body, n is the number of buckle groups, lock travel S = tooth depth x tan θ (θ is the tooth surface inclination angle).

[0184] For the buckle structure, the anti-skid thread parameters are: tooth depth: 0.5mm (light load), 0.8mm (standard), 1.0mm (heavy load), tooth spacing: 2mm (high density), 2.5mm (general), 3mm (easy to clean); handle parameters: pressing angle: 30° (power-saving type), 37.5° (balanced), 45° (fast response); knurl pitch: 1.0mm (fine thread), 1.5mm (standard), 2.0mm (coarse thread). Thread processing can use a numerical control spark forming machine (marketed as Charmilles ROBOFORM 35), and a universal material testing machine (Instron 3367) can be used for spring testing. The U-shaped hook can be made of 17-4PH precipitation hardened stainless steel (tensile strength ≥1000MPa), and the reset spring can be made of piano wire (SWP-B, Φ1.2mm, surface galvanized). The anti-skid thread is processed on the occlusion end of the hook by wire cutting, and the thread direction is at an angle of 75° with the closing direction of the top cover 8; the reset spring is hooked between the Φ3mm spring column of the base and the Φ2mm spring hole of the hook.

[0185] 4 groups of buckles on the Φ1200mm groove body measured flange surface contact pressure uniformity reached 93.5% (pressure sensitive film detection), knurled handle reduced the standard deviation of operating force under wet and slippery conditions by 62% (n=50 operation data).

[0186] In another technical solution, the cross section of the fluororubber sealing ring 10 is a trapezoidal structure, the upper base width is 6-8mm, the lower base width is 10-12mm, and the height is 5-7mm, the fluororubber sealing ring 10 is clamped on the top cover 8;

[0187] The thickness of the polyurethane elastic layer 11 compression sealing structure is 3-5mm, the compression rate is 20%-30%, and the surface is provided with a stepped occlusion groove matched with the edge of the top cover 8;

[0188] The distance between the polyurethane elastic layer 11 compression sealing structure and the fluororubber sealing ring 10 is kept at 2-4mm, forming a two-stage pressure buffer space.

[0189] In the above technical solution, specifically, for the structure parameters of the fluororubber sealing ring 10, the trapezoidal section size: upper base width: 6 mm (compact type), 7 mm (standard), 8 mm (high sealing), lower base width: 10 mm (low pressure), 11 mm (general), 12 mm (high pressure), height: 5 mm (light load), 6 mm (conventional), 7 mm (heavy load), installation pre-compression amount, initial compression rate 15% to 20%. The sealing ring can be selected from the market fluororubber trapezoidal sealing ring (Parker Hannifin PR-6T series), and the installation tool can be a pneumatic press-fit clamp (Desoutter PneuTools series). The fluororubber material can be FKM (fluorocarbon rubber, ASTM D1418 standard), and the anti-aging additive can be a bisphenol vulcanization system (temperature resistance -20℃ to 200℃). The trapezoidal groove is processed on the outside of the edge of the top cover 8, the groove depth is 7 mm, the inclination angle is 60°, the sealing ring is pressed into the trapezoidal groove by the cold shrinkage method (-40℃), and the sealing ring is expanded and locked after returning to normal temperature.

[0190] The working process is that when the top cover 8 is closed, the fluororubber sealing ring 10 is extruded to expand to the side wall of the trapezoidal groove, the lower base width 12 mm provides a radial sealing force, and the upper base width 8 mm limits excessive deformation.

[0191] Parameter setting method:

[0192] Compression rate calculation: compression rate = (original height - height after installation) / original height × 100%;

[0193] Trapezoidal groove inclination angle θ and sealing pressure relationship: tan θ = radial sealing force / axial compression force;

[0194] For the pressing structure of the polyurethane elastic layer 11, the elastic layer thickness: 3 mm (flexible), 4 mm (balanced), 5 mm (high pressure resistance); compression rate: 20% (low deformation), 25% (standard), 30% (high resilience); stepped engagement groove: depth: 0.8 mm (shallow groove), 1.0 mm (standard), 1.2 mm (deep groove); step width: 2 mm (narrow engagement), 3 mm (general), 4 mm (wide engagement). The polyurethane pouring equipment can use a high-pressure reaction injection molding machine (Hennecke HP-RTM), and the engagement groove processing can use a five-axis linkage numerical control milling machine (DMG MORIDMU 50). The polyurethane can be selected from the pouring type CPU (Bayer DP 2795A, Shore hardness 85A), and the reinforcing layer can be selected from a glass fiber mesh cloth (surface density 200 g / m 2 , interlayer clamping).

[0195] Assembly position: ladder-shaped bite groove is processed on the upper surface of the polyurethane layer, and cooperates with the metal protrusion (height 1.5 mm) of the top cover 8; compression bolts: M10 stainless steel bolts, 12 groups are uniformly distributed along the circumference of the top cover 8, and the pre-tightening torque is 25 N·m.

[0196] The working process is that when closed, the ladder-shaped groove of the polyurethane layer is engaged with the metal protrusion, 25% compression rate makes the material produce radial expansion, and fills the micro-unevenness of 0.1-0.3 mm of the flange surface.

[0197] For the two-stage pressure buffer space, the buffer space spacing is 2 mm (high pressure buffer), 3 mm (standard), and 4 mm (low pressure buffer); the pressure grading threshold is 0-0.15 MPa (fluorine rubber seal) and 0.15-0.3 MPa (polyurethane seal). The gap adjusting gasket can be a 304 stainless steel thin gasket (thickness 0.1 mm / 0.2 mm / 0.5 mm), the pressure sensor can be a piezoresistive sensor (Honeywell 24PC series), and the buffer space filling medium can be nitrogen (purity 99.99%) or silicone oil (viscosity 100 cSt).

[0198] Assembly position: the buffer space is located between the fluorine rubber ring and the polyurethane layer, and the spacing is controlled by adjusting the gasket; the pressure balance hole is a Φ2 mm micropore, which is arranged at the edge of the top cover 8 (one every 100 mm).

[0199] The working process is that when the pressure exceeds 0.15 MPa, the fluorine rubber ring deforms to reduce the buffer space, the polyurethane layer ladder-shaped groove is further compressed, and the two-stage seal is activated in turn.

[0200] The technical effects of the scheme include:

[0201] 1. Sealing grading control: the two-stage sealing makes the pressure resistance capacity increase to 0.3 MPa (0.2 MPa for single-stage structure), and the leakage rate decreases to <0.01 μL / min; the pressure buffer space absorbs 80% of the pressure fluctuation energy (verified by FFT spectrum analysis).

[0202] 2. Material synergy advantage: the chemical resistance (pH=1-13) of fluorine rubber and the elasticity (compression resilience rate >95%) of polyurethane are complementary, and the ladder-shaped bite groove design makes the assembly tolerance reach ±0.5 mm (measured by three-dimensional scanning).

[0203] 3. Long-life design: after 10,000 opening and closing cycles, the sealing performance attenuation is <10% (ASTM D395 test), and the hardness change of fluorine rubber is <5 Shore A (ASTM D2240) after 500 h of heat aging at 150°C.

[0204] 4. Maintenance economy: polyurethane layer can be cast in situ repair (curing time <4h), fluorine rubber ring replacement time <15min (modular design).

[0205] Under the pressure of 0.25MPa, the two-stage sealing structure improves the uniformity of the flange surface contact pressure from 68% to 92% (pressure sensitive film analysis), and when the buffer space is 3mm apart, the pressure impact peak attenuation rate reaches 63% (dynamic pressure sensor measurement).

[0206] In another technical solution, the circulating temperature control system comprises an electric heater, a liquid circulating pump and a temperature controller.

[0207] The liquid inlet of the liquid circulating pump is connected to the outlet end of the serpentine heat conducting pipe 13 through a first flange, and the liquid outlet is connected to the bottom interface of the external heating tank through a second flange.

[0208] The heating rod of the electric heater penetrates through the top cover 8 of the heating tank and extends below the liquid level in the tank, and the top is fixed to the surface of the top cover 8 by bolts.

[0209] The sensor interface of the temperature controller is connected to the first temperature sensor and the second temperature sensor embedded in the liquid storage cavity 3 through signal lines, and the power output terminal of the temperature controller is connected to the junction box of the electric heater through a cable.

[0210] The volume of the heating tank is 1 / 5-1 / 3 of the volume of the immersion tank 1, the flow adjustment range of the liquid circulating pump is 0.5-1.2m 3 / h, and the pump body of the liquid circulating pump is fixed to the outer side wall of the immersion tank 1 by a support.

[0211] In the above technical solution, specifically, the circulating temperature control system is composed, the volume of the heating tank: 1 / 5 (compact type), 1 / 4 (standard), 1 / 3 (large flow) of the volume of the immersion tank 1; the flow adjustment range of the circulating pump: 0.5m 3 / h (low temperature), 0.8m 3 / h (standard), 1.2m 3 / h (fast response); the power density of the heating rod: 10W / cm 2 (ordinary), 15W / cm 2 (high efficiency), 20W / cm 2 (fast heating). The electric heater can adopt a flange type tubular heater (commercial model Watlow For the FBE series, the liquid circulating pump can use a magnetic drive centrifugal pump (Grundfos Magna3 32-60), and the temperature controller can use a PID temperature controller (Omron E5CC-QX2ASM-800). The heating tank can use 316L stainless steel (wall thickness 3mm, inner wall electrolytic polishing Ra≤0.4μm), and the flange seal can use PTFE coated graphite gasket (temperature resistance 250℃).

[0212] Assembly position:

[0213] The heating tank is fixed to the side of the immersion tank 1 through a support, the center axis is 1.2m away from the ground at the bottom of the immersion tank 1; the electric heating rod penetrates the top cover 8 of the heating tank, and the heating section is immersed in the liquid surface below ≥200mm; the circulating pump base is bolted to the base frame of the immersion tank 1, and the inlet and outlet are connected by a hose.

[0214] The working process is that the circulating pump pumps the liquid in the immersion tank 1 to the heating tank through the serpentine pipe, the electric heater is warmed up to the set temperature, and then the liquid returns to the immersion tank 1 through the outlet, and the PID controller adjusts the power according to the feedback of the double sensors.

[0215] Parameter setting method:

[0216] The volume of the heating tank V=0.2V0~0.33V0(V0 is the volume of the immersion tank 1);

[0217] The length of the heating rod L=liquid level height+50mm (dry burning design).

[0218] For the temperature sensor arrangement, the first temperature sensor position: 50mm above the lowest point of the flow guide slope 7 (near the pump area), 65mm (standard), 80mm (anti-turbulence), the second temperature sensor position: 20mm below the porous baffle 2 (near the material area), 30mm (equilibrium), 40mm (far from the material area). The temperature sensor can be selected as a PT100 platinum resistance (Class A precision, commercially available model OMEGA PR-21), the signal line can be selected as a shielded twisted pair (Belden 8760 series), the sensor sleeve can be made of 316 stainless steel (outer diameter 6mm, wall thickness 1mm), and the sealing filler can be made of high temperature silicone grease (Dow Corning 340).

[0219] Assembly position:

[0220] The first sensor is embedded in the groove wall 65mm above the lowest point of the flow guide slope 7, and the probe is inserted into the liquid surface below 30mm; the second sensor is installed on the side wall 30mm below the porous baffle 2, and the horizontal angle is 45°.

[0221] Function test:

[0222] Temperature hysteresis test: compare the response time of the sensor (target≤3s);

[0223] Anti-interference test: detect signal drift (target ≤0.1℃) in a 10kV / m electromagnetic field environment.

[0224] For the operation panel integration, the display screen size: 4.3 inches (compact), 5.7 inches (standard), 7 inches (large screen), set the knob step value: 0.1℃ / grade (precision), 0.5℃ / grade (regular), 1℃ / grade (fast). The operation panel can use an industrial touch screen (Siemens SIMATIC HMI KTP400 Basic), and the wiring terminal can use a spring terminal table (Phoenix UK5N). The panel shell can be made of polycarbonate (PC, UL94 V-0 flame retardant grade), and the knob can be made of aluminum alloy anodized (surface hardness HV≥150).

[0225] Assembly position: the temperature controller is installed in the protective box outside the immersion tank 1 through the DIN rail, and the operation panel is installed on the front of the tank body at an angle of 30°, with a center height of 1.5m (in line with human engineering).

[0226] The working process is that the operator sets the target temperature through the knob, the digital screen displays the double sensor temperature value in real time, the PID algorithm automatically adjusts the heating power, and the audible and light alarm is triggered when the temperature exceeds the set value by 5℃.

[0227] Experimental method:

[0228] 1. Control precision test: set 50℃ constant temperature, record 24-hour temperature fluctuation range (target ±0.5℃);

[0229] 2. Fault simulation experiment: disconnect the single sensor signal, detect the fault tolerance of the system (automatic switching of standby sensor).

[0230] Statistical analysis: process capability analysis (CPK≥1.33) is performed on 100 groups of temperature data, and FMEA analysis (critical risk order number RPN<100) is performed on the operation error rate.

[0231] The technical effects of the present scheme include:

[0232] 1. Temperature control precision: double sensor feedback makes the temperature difference in the tank ≤±0.8℃ (traditional single sensor ±2℃), and the PID parameter self-tuning time is less than 5 minutes (60% faster than traditional temperature controller).

[0233] 2. System reliability: magnetic pump design without leakage ensures 20000 hours of maintenance-free (MTBF certification), and the surface load of the heating rod is ≤15W / cm 2 , service life ≥3 years (accelerated aging test).

[0234] 3. Operation safety: double over-temperature protection(electronic + mechanical), power off automatically when temperature > 105℃, IP65 protection grade panel dustproof and waterproof(IEC 60529 standard).

[0235] 4. Energy efficiency optimization: heat recovery design reduces energy consumption by 25%(compared with traditional steam heating), standby power consumption < 10W(measured data).

[0236] At 80℃ working condition, the temperature standard deviation σ = 0.3℃(n = 8640 data points) for 72 hours of continuous operation, and the heating system thermal efficiency reaches 92%(calculated by thermodynamic equilibrium method).

[0237] In another technical solution, a first temperature sensor is embedded at 50-80mm above the lowest point of the flow guide slope 7 of the liquid storage cavity 3, and a second temperature sensor is embedded at the groove sidewall 20-40mm below the porous baffle 2.

[0238] The temperature controller is connected with the first temperature sensor, the second temperature sensor and the electric heater through signal lines respectively;

[0239] The shell of the temperature controller is fixed to the outer wall of the immersion tank 1, and the surface is provided with a sensor interface plugged with the signal line, a power output terminal connected with the electric heater, and an operation panel integrated with a digital display screen and a temperature setting knob.

[0240] The heating rod of the electric heater extends to the inside of the heating tank and is sealingly connected with the heating tank through a flange.

[0241] In the above technical solution, specifically, for the temperature sensor installation position, the first sensor position: 50mm above the lowest point of the flow guide slope 7(near the pump area), 65mm(standard), 80mm(anti-turbulence); the second sensor position: 20mm below the porous baffle 2(near the material area), 30mm(equilibrium), 40mm(far from the material area); the sensor inclination angle: 30°(anti-deposition) with the horizontal plane, 45°(standard), 60°(anti-bubble). The temperature sensor can use PT100 platinum resistance(Class A precision, commercially available model OMEGA PR-21), the installation sleeve can use 316 stainless steel sleeve type sheath(commercially available model OMEGA TJ-36), the sensor probe rod can use 316L stainless steel(outer diameter 6mm, pressure resistance 1.6MPa), and the sealing filler can use high temperature silicone grease(Dow Corning 340).

[0242] Assembly position: the first sensor is embedded in the groove wall 65mm above the lowest point of the flow guide slope 7, and the probe rod extends into the liquid surface 30mm below; the second sensor is installed on the sidewall 30mm below the porous baffle 2, and the inclination angle with the horizontal plane is 45°.

[0243] The working process is that the first sensor monitors the liquid temperature at the pump inlet (to prevent local overheating), the second sensor detects the temperature in the immersion zone, and the double signal input PID controller realizes dynamic compensation.

[0244] The parameter setting method is that the sensor spacing ΔL = 0.2D-0.3D (D is the diameter of the tank), and the probe length L = liquid level height x 0.6 (to prevent the influence of liquid level fluctuation).

[0245] For the temperature controller connection mode, the signal line specification is shielded twisted pair (cross-sectional area 0.5mm 2 / 1.0mm 2 / 1.5mm 2 ); the power output capacity is 5kW (small), 10kW (standard), and 15kW (large). The temperature controller can use a PID temperature controller (Omron E5CC-QX2ASM-800), and the wiring terminal can use a spring terminal table (Phoenix UK 5N). The signal line sheath can use polyurethane (oil-resistant and bend-resistant), and the shell material can use polycarbonate (UL94 V-0 flame-retardant grade).

[0246] The assembly position is that the sensor interface is located at the bottom of the controller shell, the IP67 protection level socket, the power output terminal: copper bar connector (cross-sectional area 10mm 2 ), and it is installed in the control cabinet through the guide rail; the operation panel is installed on the front of the tank at an inclination of 30°, and the center height is 1.5m.

[0247] Function test:

[0248] Anti-interference test: detect signal drift (target ≤0.1℃) in a 10kV / m electromagnetic field environment.

[0249] Overload protection test: apply 120% rated power for a short time, and detect the response time of the circuit breaker (≤0.1s).

[0250] For the structure configuration of the electric heater, the flange specification is DN25 (small power), DN32 (standard), and DN40 (large power); the heating rod extension length is 100mm below the liquid surface (shallow immersion), 150mm (standard), and 200mm (deep immersion). The electric heater can use a flange type tubular heater (Watlow FBE series), and the sealing flange uses ANSI 150# RF flange (marketed model ASME B16.5-304). The heating rod can use Incoloy 800 alloy (temperature resistance 1100℃), and the sealing gasket can use PTFE coated graphite (temperature resistance 250℃).

[0251] Assembly position: heating rod penetrates through the top cover 8 of the heating tank, is fixed through a flange bolt, and extends to 150 mm below the liquid level at the lower end; the junction box: IP65 protection level, is installed on the top of the heating tank in a non-immersed liquid area.

[0252] The working process is that after the heating rod is powered on, the power is adjusted through the PID controller, and heat is transferred to the immersion tank 1 through liquid circulation. The flange sealing structure prevents medium leakage.

[0253] Experimental method:

[0254] 1. Heat distribution test: a thermocouple array is arranged in the heating tank to draw a three-dimensional temperature field (target temperature difference ≤2℃).

[0255] 2. Sealing test: 1.5 times working pressure (0.45 MPa) is applied, and the pressure is maintained for 30 minutes to detect leakage (target: no visible leakage).

[0256] Statistical analysis: Weibull distribution analysis is performed on the service life of the heating rod (shape parameter β>3.0), and Cp / Cpk process capability index calculation is performed on the temperature uniformity data (target Cp≥1.33).

[0257] The technical effects of the technical solution include:

[0258] 1. Precise temperature control: double-sensor feedback makes the temperature control accuracy reach ±0.5℃ (traditional single-sensor ±2℃), and the PID parameter self-tuning time is less than 3 minutes (actual measurement data).

[0259] 2. Safety protection: the flange sealing structure can withstand 0.3 MPa pressure (1.5 times safety factor), and the response time of double over-temperature protection (electronic + mechanical) is less than 1 second.

[0260] 3. Energy efficiency optimization: the surface load of the heating rod is ≤15W / cm 2 , the thermal efficiency is >90% (measured by heat balance method), and the standby power consumption is <5W (measured by a power meter).

[0261] 4. Friendly operation: the human-machine interface meets the IEC 61010 safety standard, the misoperation rate is reduced by 70%, and the modular design makes the heating rod replacement time <30 minutes.

[0262] In the 80℃ continuous operation test, the temperature standard deviation σ=0.28℃ (n=1000 data points), and after 5000 hours of accelerated life test, the resistance change rate of the heating rod is <2% (IEC 60335 standard).

[0263] In another technical solution, the buckle assembly includes a metal base, a U-shaped clasp, and a reset spring.

[0264] The metal base is fixed on the lower surface of the flange at the top of the groove body by bolts, and the side wall is provided with a rotating shaft groove;

[0265] The middle part of the U-shaped clamping hook is hinged to the rotating shaft groove through a rotating shaft, one end is provided with an anti-skid tooth pattern for clamping the edge of the top cover 8, and the other end is provided with an operating handle;

[0266] The two ends of the reset spring are respectively hooked between the spring column of the metal base and the spring hole of the U-shaped clamping hook;

[0267] The anti-skid tooth pattern is arranged in a sawtooth shape, the tooth depth is 0.5-1.0mm, the distance between adjacent teeth is 2-3mm, and the tooth surface and the edge of the top cover 8 form a locking stroke of 8-15mm;

[0268] The outer surface of the operating handle is provided with an anti-skid knurl, and the pressing direction and the extension direction of the reset spring form an included angle of 30-45 degrees.

[0269] In the above technical solution, specifically, for the mechanical structure of the buckle assembly, the size of the metal base, the bolt hole distance is 30mm (compact), 40mm (standard), and 50mm (heavy load), the rotating shaft groove diameter is Φ6H7 (precision fit), Φ6.5H8 (general), and Φ7H9 (fast assembly); the reset spring parameters: wire diameter Φ1.0mm (light load), Φ1.2mm (standard), Φ1.5mm (high elasticity), free length 20mm (short stroke), 25mm (general), and 30mm (long stroke). The metal base can adopt a numerical control processing 304 stainless steel block (marketed model Misumi HBLFSP30), the U-shaped clamping hook can adopt a 17-4PH stainless steel laser cutting piece (marketed model Southco C5-10-202-20), and the reset spring can adopt a piano steel wire compression spring (marketed model Lee Spring C-500). The metal base can adopt 304 stainless steel (tensile strength ≥520MPa), and the rotating shaft can adopt 420 stainless steel (surface quenching hardness HRC45-50).

[0270] Assembly position: the metal base is fixed on the lower surface of the flange at the top of the groove body by M8 stainless steel bolts, the bolt pre-tightening torque is 12N·m, the rotating shaft is pressed into the Φ6.5mm rotating shaft groove in the side wall of the base, the axial clearance is ≤0.05mm (plug gauge detection), and the reset spring is hooked between the Φ3mm spring column of the base and the Φ2.5mm spring hole of the clamping hook.

[0271] The working process is that when the top cover 8 is closed, the anti-skid tooth pattern of the U-shaped clamping hook engages the edge of the top cover 8, and the operating handle is pressed down to overcome the spring force to complete locking; when opening, the handle is lifted up, and the spring reset force reaches 20-30N.

[0272] Parameter setting method:

[0273] Spring stiffness calculation: G = string shear modulus 79 GPa, d = string diameter, D = spring diameter, n = number of effective turns;

[0274] Locking travel: S = h tan 0, h = tooth depth, 0 = tooth face angle;

[0275] For the anti-slip tooth design parameters, tooth parameters: tooth depth 0.5 mm (shallow), 0.8 mm (standard), 1.0 mm (deep), tooth spacing 2 mm (high density), 2.5 mm (general), 3 mm (easy to clean), tooth face angle 8° (low locking force), 12° (balanced), 15° (high holding force), locking travel 8 mm (short travel), 12 mm (standard), 15 mm (long travel). Tooth processing can use a numerical control wire cutting machine (Shadyk AQ325L), and surface treatment can use a shot peening device (Vilbelyt SP20). Tooth base material can use 17-4PH stainless steel (H1150M heat treatment state), and wear-resistant coating can use diamond-like carbon (DLC) coating (thickness 2 pm, friction coefficient 0.1).

[0276] Assembly position: anti-slip tooth is located at the occlusal end of the U-shaped hook, the tooth extends 15 mm, and the locking contact surface is at an angle of 75° with the closing direction of the top cover 8, and the tooth is matched with the hard chromium layer (thickness 20 pm) on the edge of the top cover 8.

[0277] Function test:

[0278] Locking force test: digital force gauge (IMADA ZTS-500N) measures 50-80 N locking force of single buckle.

[0279] Wear resistance experiment: after 10,000 opening and closing cycles, the tooth depth wear amount is less than or equal to 0.1 mm (detected by a three-dimensional profilometer).

[0280] For the ergonomic design of the operating handle, knurling parameters: pitch 1.0 mm (fine), 1.5 mm (standard), 2.0 mm (coarse), knurling depth 0.3 mm (shallow), 0.5 mm (general), 0.7 mm (high anti-slip), pressing angle 30° (power-saving type), 37.5° (balanced), 45° (fast response). Knurling processing can use numerical control knurling tool (multi-edge PTR-06), and the handle can use an aluminum alloy forged handle (commercially available model Bessey GH-38). The handle body can use 6061-T6 aluminum alloy (anodized treatment, surface hardness HV≥200), and the anti-slip layer can use vulcanized silicone rubber (Shore hardness 70A, thickness 2 mm).

[0281] Assembly position: the operating handle is welded to the end of the U-shaped hook, the center distance from the shaft is 120 mm, and the anti-slip knurling is processed on the handle gripping area, covering a length of 60 mm.

[0282] The working process is that an operator presses the handle at an angle of 30-45°, the knurling increases the friction force, one-hand operation is realized after the spring energy is released, and the required operating force is ≤40 N.

[0283] Experimental method:

[0284] 1. Ergonomic test: 50 operators repeatedly open and close the operation, and the average operating force and fatigue index (Borg scale) are recorded.

[0285] 2. Environmental adaptability test: test the coefficient of friction (target static friction coefficient ≥0.6) in an oil-stained and humid environment.

[0286] Statistical analysis: normality test of operating force data (Shapiro-Wilk, p>0.05), Spearman correlation analysis of different knurling parameters and operating comfort.

[0287] The technical effects of the technical solution include:

[0288] 1. Locking reliability: the anti-slip teeth make the anti-vibration loosening ability improved by 3 times (no loosening under 10g acceleration), and the teeth made of 17-4PH material have no corrosion after 500 hours of salt spray test (ASTM B117).

[0289] 2. Operating convenience: the knurled handle reduces the standard deviation of operating force by 58% (n=50 tests) in a wet and slippery working condition, and the 30° pressing angle design reduces the operating space requirement by 30%.

[0290] 3. Long-life design: the DLC coating reduces the tooth wear rate to 0.002 mm / 10,000 times (0.02 mm / 10,000 times for traditional carbon steel), and the spring force attenuation is less than 3% after 104 cycles (ASTM E328 test).

[0291] 4. Safety: the maximum locking force is 800 N (verified by finite element analysis), and the emergency unlocking device can be manually released within 5 seconds (actual measurement data).

[0292] On a Φ1200mm tank body, 4 groups of buckles make the flange surface contact pressure uniformity reach 94.2% (pressure sensitive film detection), when the knurling pitch is 1.5mm, the operating error rate is reduced by 72% (FMEA analysis RPN=45).

[0293] Although the embodiments of the present application have been disclosed as above, they are not limited to the application and implementation listed in the specification and embodiments, and can be fully applied to various fields suitable for the present application, and additional modifications can be easily realized by those skilled in the art, therefore the present application is not limited to specific details and the figures shown and described herein, without departing from the general concept defined by the claims and equivalent scope.

Claims

1. An impregnation device for use in a luffa processing for organic fertilizer carrier processing in a luffa processing process, characterized by, The application relates to a closed impregnation tank. The bottom of the closed impregnation tank is provided with a porous partition plate with a pore diameter of 1-3 mm, and a liquid storage cavity with a height of 100-200 mm is formed between the porous partition plate and the tank bottom. A circulating pump is connected to the bottom of the liquid storage cavity and the water outlet of the circulating pump is connected to a spray pipe 30-60 mm above the porous partition plate. The surface of the pipe body of the spray pipe is uniformly provided with conical spray holes, the interval between adjacent conical spray holes is 15-25 mm, the inlet diameter of the conical spray hole is 2-4 mm and the outlet diameter is 1-2 mm. The ratio of the pore diameter of the porous partition plate to the height of the liquid storage cavity is 1:50-100, and the ratio of the installation height of the spray pipe to the outlet diameter of the conical spray hole is 25-50:

1. The ratio of the flow of the circulating pump to the volume of the liquid storage cavity is 1-1.5 times the volume of the tank per hour, and the lift of the circulating pump is 1.2-2.0 times the total height of the impregnation tank. The bottom of the liquid storage cavity is provided with a flow guide inclined surface with an inclination angle of 3-8 degrees, and the lowest point of the flow guide inclined surface is connected to the water inlet of the circulating pump.

2. The retting apparatus for processing of organic manure carrier processing of loofa retting process as claimed in claim 1 wherein, The axis of the spray pipe and the plane of the porous partition plate form an included angle of 10-20 degrees, and the outlet direction of the conical spray hole is towards the tangent direction of the inner wall of the impregnation tank.

3. The retting apparatus for processing of luffa sponge in retting process of organic manure carrier as claimed in claim 2 wherein, A double-layer sealing structure is arranged between the top cover and the tank body of the closed impregnation tank, the outer layer is a embedded fluororubber sealing ring, and the inner layer is a polyurethane elastic laminated sealing structure. The side wall of the tank body is provided with a sandwich structure with a thickness of 20-40 mm, a serpentine heat conducting pipe is arranged in the sandwich structure, and the two ends of the heat conducting pipe are respectively connected to the liquid inlet and the liquid outlet of an external circulating temperature control system.

4. The retting apparatus for processing of organic manure carrier as claimed in claim 2 wherein, The serpentine heat conducting pipes of the sandwich structure are uniformly distributed along the circumference of the tank body, the interval between adjacent heat conducting pipes is 50-80 mm, and the ratio of the outer diameter of the heat conducting pipe to the thickness of the sandwich is 1:3 to 1:

5. The inner side of the top cover is provided with an annular flow guide cover, the taper angle of the annular flow guide cover is 60-80 degrees, and the lower edge of the annular flow guide cover is kept apart from the upper end of the spray pipe by a gap space of 50-100 mm.

5. The retting apparatus for processing of organic manure carrier processing of loofa retting process as claimed in claim 3 wherein, The outer periphery of the annular flow guide cover is provided with a sawtooth-shaped flow guide groove, the depth of the flow guide groove is 3-5 mm, and the interval between adjacent flow guide grooves is 8-12 mm.

6. The retting apparatus for processing of organic manure carrier as claimed in claim 2 wherein, The heat conducting pipe of the sandwich structure adopts a 316L stainless steel bellows, a heat conducting silicone grease layer is filled between the outer wall of the bellows and the inner wall of the sandwich, and the thickness of the heat conducting silicone grease layer is 2-5 mm.

7. The retting apparatus for processing of organic manure carrier as claimed in claim 2 wherein, The surface of the polyurethane elastic laminated sealing structure of the top cover is provided with a wave-shaped contact surface, the height difference of the wave crest is 0.5-1.2 mm, and the interval between wave troughs is 2-4 mm.

8. The retting apparatus for processing of organic manure carriers as claimed in claim 7 wherein, In the double-layer sealing structure, 2-4 groups of buckle assemblies are uniformly distributed along the circumference of the tank body. The cross section of the fluororubber sealing ring is a trapezoidal structure, the upper bottom width is 6-8 mm, the lower bottom width is 10-12 mm, and the height is 5-7 mm. The fluororubber sealing ring is clamped on the top cover.

9. The retting apparatus for processing of organic manure carrier processing of loofa retting process as claimed in claim 3 wherein, The thickness of the polyurethane elastic laminated sealing structure is 3-5 mm, the compression rate is 20%-30%, and the surface is provided with a stepped engagement groove matched with the edge of the top cover. The interval between the polyurethane elastic laminated sealing structure and the fluororubber sealing ring is kept at 2-4 mm to form a double-stage pressure buffer space. The circulating temperature control system comprises an electric heater, a liquid circulating pump and a temperature controller. The liquid inlet of the liquid circulating pump is connected with the outlet end of the serpentine heat pipe through a first flange, and the liquid outlet is connected with the bottom interface of the external heating tank through a second flange; The heating rod of the electric heater penetrates through the top cover of the heating tank and extends below the liquid level in the tank, and the top of the heating rod is fixed to the surface of the top cover through bolts; The sensor interface of the temperature controller is connected with the first temperature sensor and the second temperature sensor embedded in the liquid storage cavity through signal lines respectively, and the power output terminal of the temperature controller is connected with the junction box of the electric heater through an electric cable; The heating tank volume is 1 / 5-1 / 3 of the volume of the immersion tank, the flow adjustment range of the liquid circulating pump is 0.5-1.2 m 3 / h, and the pump body of the liquid circulating pump is fixed to the outer side wall of the immersion tank through a support.

10. The retting apparatus for processing of organic manure carriers as claimed in claim 9 wherein, The first temperature sensor is embedded above the lowest point of the flow guide slope of the liquid storage cavity by 50-80 mm, and the second temperature sensor is embedded in the groove side wall below the porous partition by 20-40 mm; The temperature controller is connected with the first temperature sensor, the second temperature sensor and the electric heater through signal lines respectively; The shell of the temperature controller is fixed to the outer wall of the immersion tank, and the surface of the shell is provided with a sensor interface plugged with the signal lines, a power output terminal connected with the electric heater, and an operation panel integrated with a digital display screen and a temperature setting knob; The heating rod of the electric heater extends to the inside of the heating tank and is sealingly connected with the heating tank through a flange.

Images