A length compensator seal early warning processing device

Abstract

This utility model relates to the field of length compensators, specifically to a sealing early warning processing device for length compensators. The device includes a grease storage tank, connecting pipes, an electric pump, a solenoid valve, a pressure sensor, and a controller. The grease storage tank stores sealing grease. One end of the connecting pipe is connected to the grease storage tank, and the other end is positioned between the sealing rings of the length compensator. The electric pump and solenoid valve are located on the connecting pipe and are used to control the delivery of sealing grease. The pressure sensor monitors the pressure between the sealing rings in real time, and the controller controls the electric pump and solenoid valve based on the pressure signal, achieving automatic replenishment of sealing grease and real-time monitoring of the sealing status. This device can replenish sealing grease in a timely manner and issue an early warning, effectively solving the problem of the lack of automatic sealing grease replenishment and intelligent early warning functions in existing technologies.

Description

Technical Field

[0001] This utility model relates to the field of length compensators, specifically to a sealing early warning processing device for length compensators. Background Technology

[0002] In piping systems, length compensators are crucial components used to address length variations caused by temperature changes, pressure fluctuations, or mechanical stress. However, existing length compensators suffer from several shortcomings in sealing performance and early warning capabilities. For instance, traditional length compensators typically rely solely on sealing rings for sealing, which can easily lead to leakage if the rings fail. Furthermore, existing technologies lack a comprehensive measurement, monitoring, and early warning system, failing to detect seal failures promptly and issue warnings. This increases maintenance costs and safety risks. For example, patent CN109723389A discloses a length compensation device that primarily achieves sealing and pressure balance through a nested design of inner and outer pipes and the placement of a balancing piston. However, this patent does not address automatic grease replenishment or intelligent seal warning functions.

[0003] Therefore, this application proposes a novel length compensator sealing early warning processing device. Utility Model Content

[0004] The purpose of this invention is to provide a sealing early warning processing device for a length compensator, so as to solve the problem that the existing technology lacks effective automatic grease replenishment and intelligent sealing early warning functions.

[0005] To achieve the above objectives, the following technical solution is adopted.

[0006] A length compensator sealing early warning processing device, comprising,

[0007] Grease storage tank, used to store sealing grease;

[0008] A connecting pipe, the first end of which is connected to the grease tank, and the second end which is located between the first and second sealing rings of the length compensator;

[0009] An electric pump is installed on the connecting pipe, and the electric pump is connected to the grease storage tank through the connecting pipe;

[0010] A solenoid valve is disposed on the connecting pipeline and is located between the electric pump and the second end of the connecting pipeline;

[0011] A pressure sensor is disposed between the first sealing ring and the second sealing ring of the length compensator for real-time monitoring of the pressure between the first sealing ring and the second sealing ring of the length compensator.

[0012] The controller is connected to the pressure sensor, the solenoid valve, and the electric pump, and is used to receive pressure signals and control the operation of the solenoid valve and the electric pump.

[0013] Optionally, it may also include an audible and visual alarm device, which is electrically connected to the controller.

[0014] Optionally, a one-way valve is also included, which is disposed on the connecting pipeline. The one-way valve is located between the solenoid valve and the second end of the connecting pipeline and is used to allow the sealing grease in the grease tank to flow out when opened, preventing backflow.

[0015] Optionally, the pressure sensor is located at the second end of the connecting pipe.

[0016] Optionally, it also includes a housing, in which the grease tank, electric pump, solenoid valve and controller are all housed, and the housing is fixed to the outside of the length compensator.

[0017] Optionally, the second end of the connecting pipe is provided with an annular diffuser, which is sleeved between the first sealing ring and the second sealing ring of the length compensator, and the annular diffuser has multiple radial injection holes distributed circumferentially on its outer edge.

[0018] Optionally, the pressure sensors are in multiple sets, arranged in a ring array along the annular diffuser.

[0019] Optionally, the annular diffuser is formed by connecting pipes, and the annular diffuser is not connected end to end.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] This application achieves automatic grease replenishment and real-time monitoring of the sealing status by incorporating a grease reservoir, an electric pump, a solenoid valve, a pressure sensor, and a controller. It not only replenishes the grease promptly to prevent leaks due to insufficient grease, but also monitors the sealing status in real time via the pressure sensor. If an abnormal pressure is detected, the controller can promptly activate the electric pump and solenoid valve to replenish the grease and issue an early warning, thus effectively solving the problem of the lack of effective automatic grease replenishment and intelligent sealing warning functions in existing technologies.

[0022] In addition, the installed audible and visual alarm device can issue an audible and visual alarm when abnormal pressure is detected, reminding operators to handle it in time; the one-way valve can prevent the backflow of sealing grease and ensure the one-way flow of sealing grease; the pressure sensor is set at the second end of the connecting pipeline, which can monitor the sealing status more accurately; the housing design can integrate all the components of the device into one housing, which is convenient for installation and maintenance; the annular diffuser and multiple sets of pressure sensors are distributed along the annular array, which can distribute the sealing grease more evenly and monitor the sealing status more comprehensively, further improving the reliability and safety of the device. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of an embodiment of a length compensator sealing early warning processing device according to the present invention.

[0024] The components include: 1. Grease storage tank; 2. Connecting pipeline; 3. Electric pump; 4. Solenoid valve; 5. Check valve; 6. Pressure sensor; 7. Controller; 8. Length compensator; 9. First sealing ring; 10. Second sealing ring; 11. Audible and visual alarm device. Detailed Implementation

[0025] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0026] The following detailed description is exemplary and intended to provide further detailed explanation of the present invention. Unless otherwise specified, all technical terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. The terminology used in this invention is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to the present invention.

[0027] like Figure 1 As shown, this utility model provides a length compensator sealing early warning and processing device, which aims to solve the problem that the sealing failure of the length compensator 8 cannot be detected and handled in a timely manner in the prior art through intelligent sealing grease replenishment and real-time pressure monitoring.

[0028] The grease reservoir 1 is one of the core components of this device, and its main function is to store sealing grease. Sealing grease is a material with high viscosity and good sealing performance, typically used to fill the gaps between the sealing rings of the length compensator 8 to prevent leakage. In this embodiment, the grease reservoir 1 is made of pressure-resistant and corrosion-resistant materials, such as stainless steel or high-strength plastic, to ensure its long-term stable use in complex industrial environments. The capacity of the grease reservoir 1 can be designed according to the size of the length compensator 8 and the sealing requirements. For example, for small length compensators 8, the capacity of the grease reservoir 1 can be designed to be 1 liter to 5 liters; for large length compensators 8, the capacity of the grease reservoir 1 can be designed to be 10 liters to 50 liters.

[0029] When selecting sealant, optimization can be made based on different working environments and media characteristics. For example, in high-temperature environments, high-temperature resistant sealant, such as polytetrafluoroethylene (PTFE) based sealant, can be selected; in chemical media environments, chemically resistant sealant, such as fluororubber based sealant, can be selected. Furthermore, sealant can be supplemented with additives such as antioxidants and rust inhibitors to improve its service life and performance.

[0030] Connecting pipe 2 serves as the channel between the grease reservoir 1 and the length compensator 8, and its design directly affects the grease delivery efficiency and the reliability of the device. In this embodiment, connecting pipe 2 is made of pressure-resistant and corrosion-resistant materials, such as stainless steel or polytetrafluoroethylene (PTFE). The first end of connecting pipe 2 is connected to the grease reservoir 1, and the second end is positioned between the first sealing ring 9 and the second sealing ring 10 of the length compensator 8. To ensure smooth grease delivery, the inner diameter of connecting pipe 2 can be designed according to the viscosity and flow rate of the grease. For example, for high-viscosity grease, the inner diameter of connecting pipe 2 can be designed to be 10 mm to 20 mm; for low-viscosity grease, the inner diameter can be designed to be 5 mm to 10 mm.

[0031] In the design of connecting pipe 2, multiple branch pipes can also be considered to achieve multi-point grease injection. For example, branch pipes can be set at multiple sealing positions of the length compensator 8, and the solenoid valves 4 of each branch pipe can be controlled by the controller 7 to achieve independent grease injection at different sealing positions. This multi-point grease injection design can further improve the sealing effect and ensure uniform distribution of sealing grease.

[0032] The electric pump 3 is the power source for conveying the sealant grease, and its performance directly affects the conveying efficiency and the response speed of the device. In this embodiment, a high-precision, high-reliability micro electric pump 3 is used, which can accurately control the amount of sealant conveyed according to the instructions of the controller 7. The power of the electric pump 3 can be selected according to the viscosity of the sealant grease and the conveying distance. For example, for a small length compensator 8, the power of the electric pump 3 can be designed to be 10 watts to 50 watts; for a large length compensator 8, the power of the electric pump 3 can be designed to be 100 watts to 500 watts.

[0033] Solenoid valve 4 is installed on connecting pipe 2, located between electric pump 3 and the second end of connecting pipe 2, and is used to control the flow of sealing grease. In this embodiment, solenoid valve 4 is a high-response solenoid valve, which can quickly switch the flow state of sealing grease under the command of controller 7. The diameter of solenoid valve 4 can be designed according to the inner diameter of connecting pipe 2 to ensure that sealing grease can pass through smoothly. For example, when the inner diameter of connecting pipe 2 is 10 mm, the diameter of solenoid valve 4 can be designed to be 8 mm to 10 mm.

[0034] The coordinated control of electric pump 3 and solenoid valve 4 is one of the key technologies of this device. Controller 7 controls the operation of electric pump 3 and solenoid valve 4 in real time based on the pressure signal detected by pressure sensor 6. For example, when pressure sensor 6 detects that the pressure between the sealing rings of length compensator 8 is lower than a set threshold, controller 7 starts electric pump 3 and opens solenoid valve 4, delivering sealing grease from grease tank 1 to between the sealing rings until the pressure returns to the normal range. Through this coordinated control, the device can automatically replenish sealing grease, effectively preventing seal failure.

[0035] The pressure sensor 6 is the core monitoring component of this device, and its function is to monitor the pressure between the sealing rings of the length compensator 8 in real time. In this embodiment, the pressure sensor 6 is a high-precision, high-reliability pressure sensor, capable of accurately detecting minute pressure changes. The range of the pressure sensor 6 can be selected according to the working pressure range of the length compensator 8. For example, for a length compensator 8 with a working pressure of 0.1 MPa to 1 MPa, the range of the pressure sensor 6 can be designed to be 0 to 1.5 MPa.

[0036] The controller 7 is the intelligent control core of this device. Its function is to receive the pressure signal from the pressure sensor 6 and control the operation of the electric pump 3 and the solenoid valve 4 according to the preset control logic. In this embodiment, the controller 7 adopts a high-performance microcontroller 7, which has data acquisition, processing, and control functions. The controller 7 can determine the sealing status in real time based on the pressure signal from the pressure sensor 6. For example, when the pressure detected by the pressure sensor 6 is lower than the set threshold, the controller 7 determines that there may be a leak between the sealing rings, and then starts the electric pump 3 and the solenoid valve 4 to replenish the sealing grease. At the same time, the controller 7 can also record historical data of pressure changes and predict the service life of the sealing grease and the wear of the sealing rings through data analysis.

[0037] To improve monitoring accuracy, this device can also be equipped with multiple pressure sensors 6, installed at different sealing positions of the length compensator 8. Through multi-point pressure monitoring, the controller 7 can gain a more comprehensive understanding of the sealing status and promptly detect potential leaks. For example, by installing pressure sensors 6 at the sealing positions at both ends of the length compensator 8, when the pressure at both ends drops simultaneously, the controller 7 can determine that the sealing grease is insufficient; when the pressure at one end drops while the pressure at the other end remains normal, the controller 7 can determine that the sealing ring at that end has failed.

[0038] This device also includes an audible and visual alarm device 11, which functions to issue an audible and visual alarm signal when a sealing abnormality is detected, reminding the operator to handle the situation promptly. The audible and visual alarm device 11 is electrically connected to the controller 7, which determines the sealing status based on the pressure signal from the pressure sensor 6. When the pressure detected by the pressure sensor 6 is lower than a set threshold, the controller 7 activates the audible and visual alarm device 11, issuing an audible and visual alarm signal.

[0039] The audible and visual alarm device 11 can be designed in various ways. For example, the audible alarm section can use a high-volume buzzer, the alarm volume of which can be adjusted according to the noise level of the working environment. The visual alarm section can use a high-brightness LED light, which emits an alarm signal by flashing. To improve the visibility of the alarm, the LED light can be installed in a conspicuous position on the length compensator 8, such as the top or side of the housing.

[0040] Furthermore, the audible and visual alarm device 11 can also be connected to a remote monitoring system to transmit alarm signals to the control room or the operator's mobile device. For example, through a wireless communication module, the audible and visual alarm device 11 can send alarm signals to the operator's mobile phone or tablet, reminding the operator to take timely measures. This remote alarm function can effectively improve the safety and reliability of equipment, especially in unattended industrial environments.

[0041] This device also includes a one-way valve 5, which functions to prevent the backflow of sealing grease. The one-way valve 5 is located on the connecting pipe 2, between the solenoid valve 4 and the second end of the connecting pipe 2. When the electric pump 3 starts and the sealing grease is transported from the grease tank 1 to between the sealing rings, the one-way valve 5 opens, allowing the sealing grease to flow out; when the electric pump 3 stops working, the one-way valve 5 closes, preventing the sealing grease from flowing back.

[0042] The check valve 5 can be designed in various ways. For example, a spring-loaded check valve 5 can be used, where the spring force enables one-way opening and closing. The advantages of the spring-loaded check valve 5 are its simple structure and high reliability. Another design is a ball valve check valve 5, where the movement of a ball enables one-way opening and closing. The advantages of the ball valve check valve 5 are its good sealing performance, effectively preventing the leakage of sealing grease.

[0043] To further improve the reliability of the one-way valve 5, this device can also be equipped with multiple one-way valves 5, installed at different locations in the connecting pipeline 2. For example, one-way valves 5 can be installed in the middle of the connecting pipeline 2 and near the sealing ring, respectively, to ensure the one-way flow of the sealing grease through a double anti-backflow design.

[0044] Pressure sensor 6 is located at the second end of connecting pipe 2. It allows for more direct monitoring of the pressure of the sealing grease between the sealing rings, improving monitoring accuracy. The installation position of pressure sensor 6 can be optimized according to the structure of the sealing ring and sealing requirements. For example, for annular sealing rings, pressure sensor 6 can be installed at the center of the annular sealing ring; by detecting pressure changes at the center, the sealing status can be determined.

[0045] Furthermore, pressure sensors 6 can be installed at multiple locations along the connecting pipe 2 to achieve multi-point pressure monitoring. For example, pressure sensors 6 can be installed in the middle of the connecting pipe 2 and near the sealing ring. By comparing pressure changes at different locations, the flow state of the sealing grease and the sealing performance of the sealing ring can be determined. This multi-point pressure monitoring design can further improve the accuracy of monitoring and promptly detect potential leaks.

[0046] This device also includes a housing, within which the grease tank 1, electric pump 3, solenoid valve 4, and controller 7 are all housed. The housing design not only protects the internal components from external environmental influences but also allows for integrated and modular design. The housing is made of pressure-resistant and corrosion-resistant materials, such as stainless steel or high-strength plastic. The shape of the housing can be designed according to the structure of the length compensator 8 and the available installation space. For example, for a circular length compensator 8, the housing can be designed as a cylinder; for a square length compensator 8, the housing can be designed as a cuboid.

[0047] The internal structure of the housing can be optimized based on the layout of each component. For example, the grease tank 1 can be installed at one end of the housing, the electric pump 3 and solenoid valve 4 can be installed in the middle of the housing, and the controller 7 can be installed at the other end of the housing. Through a reasonable layout, the housing can achieve effective protection and integrated design for each component. In addition, the housing can be equipped with heat dissipation holes and ventilation holes to ensure effective heat dissipation during operation.

[0048] The second end of the connecting pipe 2 is equipped with an annular diffuser, which is fitted between the first sealing ring 9 and the second sealing ring 10 of the length compensator 8. Multiple radial injection holes are distributed circumferentially on the outer edge of the annular diffuser to evenly spray sealant between the sealing rings. This design improves the uniformity of sealant distribution and further enhances the sealing effect.

[0049] The structure of the annular diffuser can be optimized according to the size of the sealing ring and sealing requirements. For example, the diameter of the annular diffuser can be matched with the outer diameter of the sealing ring to ensure that the sealing grease can be evenly sprayed between the sealing rings. The number and distribution of the injection holes of the annular diffuser can be designed according to the flow rate and spray range of the sealing grease. For example, for a small length compensator 8, the annular diffuser can be provided with 10 to 20 injection holes; for a large length compensator 8, the annular diffuser can be provided with 30 to 50 injection holes.

[0050] Multiple pressure sensors 6 are arranged in a ring array along the outer side of the annular diffuser. This design enables multi-point monitoring of the pressure between the sealing rings, improving the accuracy and comprehensiveness of the monitoring. The layout of the multiple pressure sensors 6 can be optimized according to the structure of the sealing rings and the sealing requirements. For example, the pressure sensors 6 can be evenly distributed along the outer side of the annular diffuser, and by detecting pressure changes at different locations, the uniformity of the grease distribution and the sealing performance of the sealing rings can be determined.

[0051] Furthermore, multiple pressure sensors 6 can be combined with the intelligent algorithm of the controller 7 to achieve real-time analysis and prediction of the sealing status. For example, by comparing pressure changes at different locations, the controller 7 can determine the flow status of the sealing grease and the wear condition of the sealing ring. When the pressure at a certain location continues to drop, the controller 7 can determine that there may be a leak in the sealing ring at that location, promptly start the electric pump 3 and the solenoid valve 4 to replenish the sealing grease, and issue an audible and visual alarm signal.

[0052] In the above embodiments, the various technical features of this device can be further expanded and optimized according to different application scenarios and requirements. For example, the capacity and material of the grease tank 1 can be adjusted according to the size of the length compensator 8 and the working environment; the power and model of the electric pump 3 can be selected according to the viscosity of the sealing grease and the conveying distance; the range and accuracy of the pressure sensor 6 can be optimized according to the working pressure range of the length compensator 8; and the control logic and algorithm of the controller 7 can be adjusted according to the service life of the sealing grease and the wear of the sealing ring.

[0053] Furthermore, this device can be combined with other technical solutions to further improve its performance and reliability. For example, it can be integrated with the temperature monitoring system of the length compensator 8 to predict changes in the viscosity of the sealing grease by monitoring temperature variations, thereby optimizing the delivery speed of the electric pump 3 and the opening time of the solenoid valve 4. It can also be integrated with the leakage detection system of the length compensator 8 to further optimize the sealing grease replenishment strategy and the timing of audible and visual alarm signals by detecting the location and amount of leakage.

[0054] In summary, this utility model provides a sealing early warning and handling device for length compensators. Through intelligent grease replenishment and real-time pressure monitoring, it effectively solves the problem of untimely detection and handling of sealing failures in existing technologies. The various technical features of this device can be optimized and expanded according to different application scenarios and needs, possessing broad application prospects and practical significance.

[0055] As is known from common technical knowledge, this utility model can be implemented through other embodiments that do not depart from its spirit or essential characteristics. Therefore, the disclosed embodiments described above are merely illustrative in all respects and are not the only ones. All modifications within the scope of this utility model or its equivalents are included in this utility model.

Claims

1. A length compensator seal early warning processing device, characterized by, include, Grease storage tank (1), used to store sealing grease; Connecting pipe (2), the first end of the connecting pipe (2) is connected to the grease tank (1), and the second end is set between the first sealing ring (9) and the second sealing ring (10) of the length compensator (8); An electric pump (3) is installed on the connecting pipe (2), and the electric pump (3) is connected to the fat storage tank (1) through the connecting pipe (2); Solenoid valve (4), the solenoid valve (4) is disposed on the connecting pipe (2), the solenoid valve (4) is located between the electric pump (3) and the second end of the connecting pipe (2); A pressure sensor (6) is disposed between the first sealing ring (9) and the second sealing ring (10) of the length compensator (8) for real-time monitoring of the pressure between the first sealing ring (9) and the second sealing ring (10) of the length compensator (8); The controller (7) is connected to the pressure sensor (6), the solenoid valve (4) and the electric pump (3) to receive pressure signals and control the operation of the solenoid valve (4) and the electric pump (3).

2. A length compensator seal early warning processing device according to claim 1, wherein, It also includes an audible and visual alarm device (11), which is electrically connected to the controller (7).

3. The length compensator seal early warning processing device of claim 1, wherein, It also includes a one-way valve (5) disposed on the connecting pipe (2). The one-way valve (5) is located between the solenoid valve (4) and the second end of the connecting pipe (2) and is used to allow the sealing grease in the grease tank (1) to flow out when opened, preventing backflow.

4. The length compensator seal early warning processing device of claim 1, wherein, The pressure sensor (6) is located at the second end of the connecting pipe (2).

5. The length compensator seal early warning processing device of claim 1, wherein, It also includes a housing, in which the grease tank (1), electric pump (3), solenoid valve (4) and controller (7) are all housed, and the housing is fixed to the outside of the length compensator (8).

6. The length compensator seal early warning processing device of claim 1, wherein, The second end of the connecting pipe (2) is provided with an annular diffuser, which is sleeved between the first sealing ring (9) and the second sealing ring (10) of the length compensator (8). The annular diffuser has multiple radial injection holes distributed circumferentially on its outer edge.

7. A length compensator seal early warning processing device according to claim 6, wherein, There are multiple sets of pressure sensors (6), which are arranged in a ring array along the outside of the annular diffuser.

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