Pickling device and pickling method for hot water storage tank

Abstract

This pickling device (60) performs a pickling treatment on a cylindrical hot water storage tank (10). The pickling device (60) comprises: a rolling roller (201) that, in a state in which the cylindrical central axis of the hot water storage tank (10) is laid horizontally, comes into contact with a portion of a body (101) of the hot water storage tank (10) from below, and rolls the hot water storage tank (10); a liquid injection / discharge device (30) that injects and discharges a cleaning liquid to and from the hot water storage tank (10), and supplies and exhausts air; and an exhaust device (50) that prevents splashing of various washing liquids and scattering of generated gas.

Description

Pickling equipment and method for pickling hot water storage tank

[0001] The present disclosure relates to a pickling apparatus and a method for pickling a hot water storage tank.

[0002] For example, the immersion method, which is a chemical cleaning method in which the object to be treated is immersed in a tank filled with an acid pickling solution, is widely used to clean the hot water storage tank used in a water heater.

[0003] To date, many prior art technologies related to shaking have been developed to eliminate air pockets, which are the main cause of poor cleaning in immersion methods. Patent Document 1 describes a method in which an immersion tank is equipped with a shaking bucket to shake the workpiece. Patent Document 2 describes a method in which an immersion jig is provided with a shaking mechanism and the workpiece is shaken by a lifting device placed in the immersion tank. Furthermore, Patent Document 3 describes a method in which a conveying device is provided with a shaking mechanism to shake the workpiece.

[0004] JP-A-1-119695 Patent No. 6946606 Utility Model Application No. 63-014573

[0005] The conventional immersion method has three main issues. First, poor immersion properties. Loading the workpiece into the hot water tank takes time to eliminate air pockets. Furthermore, removing the workpiece from the tank also takes time to reduce the amount of cleaning solution carried out, making the pickling process a bottleneck process and reducing productivity.

[0006] Second, the equipment becomes larger. The provision of a swinging mechanism increases the size of the immersion tank or the transport machine. Furthermore, a large number of large tanks must be installed to transport the workpieces from tank to tank. Furthermore, the entire equipment must be enclosed in a casing to prevent splashes of the pickling solution or the dispersion of generated gas, which increases the size of the entire equipment.

[0007] Third, the working environment deteriorates. In an environment where a nitric-hydrofluoric acid-based pickling solution is used, workers must wear protective clothing because splashes or generated gases from the pickling solution are dispersed, which increases the workload.

[0008] The present disclosure has been made in consideration of the above circumstances, and aims to provide a pickling apparatus and a method for pickling a hot water storage tank that can pickle a hot water storage tank in a short time, reduce the size of the entire apparatus, and improve the working environment.

[0009] In order to achieve the above object, the pickling apparatus of the present disclosure is an apparatus for performing pickling treatment on a cylindrical hot water storage tank, and is equipped with rolling rollers that contact the body of the hot water storage tank from below and roll the hot water storage tank while the cylindrical central axis of the hot water storage tank is laid horizontally, an inlet / outlet device that injects / drains cleaning liquid into the hot water storage tank and supplies / exhausts air, and an exhaust device that prevents splashes of various cleaning liquids and scattering of generated gases.

[0010] In this disclosure, cleaning liquid is poured into and discharged from the hot water storage tank, and air is supplied and exhausted from the hot water storage tank, causing the hot water storage tank to rotate for cleaning. An exhaust device also prevents splashes of various cleaning liquids and the dispersion of generated gas. This allows the hot water storage tank to be pickled in a short time, the entire equipment to be made smaller, and the working environment to be improved.

[0011] (a) A side view, (b) a front view of a positioning device according to the first embodiment of the present disclosure. (c) A side view, (b) a view taken along arrows A-A in (a), and (c) a view taken along arrows B-B in (b) of the positioning device according to the first embodiment of the present disclosure. (a) A flowchart of the operation of the manual work, (b) a rolling device, and a positioning device according to the first embodiment of the present disclosure. (b) A flowchart of the operation of the filling and draining device and the exhaust device according to the first embodiment of the present disclosure. FIG. 1 is a flowchart of the operation of the rolling device and the positioning device by manual operation. FIG. 2 is a flowchart of the operation of (a) the liquid injection and drainage device and (b) the exhaust device according to the first embodiment of the present disclosure. FIG. 3 is a flowchart of the operation of (a) the rolling device and the positioning device, (b) the exhaust device, and (c) the manual operation according to the first embodiment of the present disclosure.

[0012] Hereinafter, specific embodiments of the pickling apparatus according to the present disclosure will be described with reference to the accompanying drawings. However, the present disclosure is not limited to the following embodiments.

[0013] 1 shows an overall view of a hot water storage tank 10 according to a first embodiment of the present disclosure. In the following figures, the axial directions are described using a first axis, a second axis, and a third axis that are perpendicular to each other. Note that the direction indicated by the arrow of the second axis is the upper side, and the direction indicated by the arrow of the third axis is the front side.

[0014] The hot water storage tank 10, which is the object to be treated, is a can product including a cylindrical body 101 and bowl-shaped upper and lower end plates 102 and 103. The hot water storage tank 10 is a medium-sized cylindrical container with a capacity of approximately 200 L to 600 L. The hot water storage tank 10 is rotated around the first axis with its cylindrical central axis aligned with a first axial direction.

[0015] The body 101 has different outer shapes and lengths depending on the type of container. The body 101 has a cylindrical boss 111 on its circumference, which serves as an inlet and outlet for liquid when cleaning the hot water storage tank 10. The central axis of the boss 111 is perpendicular to the first axis. A liquid inlet / drain coupler 112 is attached to the liquid inlet / outlet portion of the boss 111. For example, cleaning liquid is supplied to the hot water storage tank 10 by injecting liquid into the boss 111 with the second axis pointing upward as shown in FIG. 1( a), and the liquid is drained with the second axis pointing downward as shown in FIG. 1( b).

[0016] The body 101 is provided with one or more bosses at positions other than the illustrated boss 111, but these are not shown in the figure. The bosses other than the boss 111 are sealed.

[0017] The upper end plate 102 has a boss 121 that serves as an inlet and outlet for gas when cleaning the hot water storage tank 10. The cylindrical center axis of the boss 121 is horizontal to the first axis. An intake and exhaust coupler 122 is attached to the boss 121, and serves as both a point for releasing internal pressure when pouring liquid and a point for applying air pressure when draining liquid.

[0018] The upper head 102 is provided with one or more bosses at positions other than the illustrated boss 121, but these are not shown. The bosses other than the boss 121 are sealed. In this embodiment, the lower head 103 is not provided with any bosses.

[0019] 2 shows an overall view of rolling device 20 according to the first embodiment of the present disclosure. Note that in FIG. 2, descriptions of devices other than rolling device 20 shown in FIG. 3 are omitted.

[0020] The rolling device 20 rolls the hot water storage tank 10. The rolling device 20 includes a roller base 276, a rolling roller 201, a guide roller 202, a movable shaft 203, a drive mechanism 205, and a fall prevention mechanism 21. The roller 201, the guide roller 202, and the movable shaft 203 are provided on the upper part of the roller base 276.

[0021] The rolling roller 201 has four rolling elements and supports the body 101 of the hot water storage tank 10 from below. Of the four rolling elements, two rolling elements on one side as viewed in the first axial direction are rotated by a drive mechanism 205 connected to the rolling elements, and transmit power to the hot water storage tank 10. The other two rolling elements are driven rollers. In this way, the rolling roller 201 rolls the hot water storage tank 10 in place.

[0022] The guide roller 202 has four rolling elements and contacts the lower tangential direction of the spherical surface portions of the upper head plate 102 and the lower head plate 103. Therefore, the support of the guide roller 202 is attached so as to extend obliquely toward the outer surface of the upper head plate 102 or the lower head plate 103. The guide roller 202 guides the hot water storage tank 10 in the first axial direction while it is rolling.

[0023] The movable shaft 203 extends in a first axial direction and moves the rolling rollers 201 and guide rollers 202 on the upper end plate 102 side in the first axial direction. The rolling rollers 201 and guide rollers 202 on the upper end plate 102 side have the movable shaft 203 in the first axial direction, allowing hot water storage tanks 10 with different body lengths to roll.

[0024] The fall prevention mechanism 21 includes two guide rollers 211 and a movable shaft 212. Each guide roller 211 includes two rolling elements that contact the body 101 from above. The movable shaft 212 moves the guide rollers 211 in the second axial direction. When performing the rolling operation, the guide rollers 211 contact the body 101 to guide the hot water storage tank 10. When performing the loading / unloading operation, the guide rollers 211 are moved to a non-interference position. This allows for the installation of hot water storage tanks 10 with different body diameters and prevents them from falling off.

[0025] The rolling device 20 further includes a positioning device 40, a housing 271, a safety door 273, an operation button 274, a mounting plate 275, a liquid discharge section 277, an air inlet 278, and an air outlet 279. Details of the positioning device 40 will be described later with reference to FIG.

[0026] Housing 271 is formed in a rectangular parallelepiped shape and houses the above-mentioned components of positioning device 40. Housing 271 has opening 272 that opens to the operator side. Safety door 273 is an openable door that covers opening 272. Operation button 274 is a button that the operator presses to perform operations such as rolling and stopping hot water storage tank 10 and opening and closing safety door 273.

[0027] The mounting plate 275 is a thick plate-like part fixed deep inside the housing 271 as seen by an operator. The movable shaft 212 of the fall-off prevention mechanism 21 is fixed to the mounting plate 275. The liquid discharge part 277 is provided on the upper part of the roller base 276. The liquid discharge part 277 has a recess that receives the cleaning liquid when the hot water storage tank 10 is drained, and a hole that discharges the liquid further downward from the recess. An air inlet 278 and an exhaust port 279 are provided in the housing 271. The air inlet 278 and the exhaust port 279 are openings for ventilating the inside of the housing 271.

[0028] 3 shows a system diagram of a pickling apparatus 60 according to the first embodiment of the present disclosure. The pickling apparatus 60 is an apparatus that performs pickling treatment on a steel hot water storage tank 10.

[0029] In addition to the rolling device 20, the pickling apparatus 60 includes a liquid injection / drainage device 30, an exhaust device 50, and a control unit 500. The liquid injection / drainage device 30 injects and drains various cleaning liquids into the hot water storage tank 10. The exhaust device 50 prevents splashes of the various cleaning liquids or generated gas from scattering.

[0030] The liquid injection / drainage device 30 in FIG. 3 includes a liquid injection nozzle section 31, a supply / exhaust section 32, a liquid drainage nozzle section 33, and a liquid circulation section .

[0031] The tip of the injection nozzle 31 is provided with an injection coupler 311 and a rotary valve 312 for switching the type of supply liquid. The injection nozzle 31 has movable axes in the first, second, and third axial directions and is driven by an actuator (not shown). After the injection nozzle 31 moves from its original position to its set position, the pickling apparatus 60 detects the position of the injection and drainage coupler 112 using, for example, image recognition. After detection, the pickling apparatus 60 determines the amount of position correction in the first and third axial directions. After the correction operation is completed, the injection nozzle 31 can move in the second axial direction to connect the injection and drainage coupler 311 and the injection and drainage coupler 112.

[0032] The tip of the supply and exhaust unit 32 is provided with a supply and exhaust coupler 321 and a rotary valve 322. The injection nozzle unit 32 has movable axes in the first, second, and third axial directions and is driven by an actuator (not shown). After the injection nozzle unit 32 moves from its original position to its set position, the pickling apparatus 60 detects the position of the supply and exhaust coupler 122, for example, using image recognition. After detection, the pickling apparatus 60 determines the position correction amounts in the second and third axial directions. After the position correction operation is complete, the supply and exhaust unit 32 can move in the first axial direction to connect the supply and exhaust coupler 321 and the supply and exhaust coupler 122. During injection, the supply and exhaust unit 32 allows air to escape from the hot water storage tank 10 without actively evacuating it. Furthermore, during drainage, the supply and exhaust unit 32 actively pressurizes the hot water storage tank 10.

[0033] A drainage coupler 331 and a rotary valve 332 are provided at the tip of the drainage nozzle 33. The drainage unit 33 has movable axes in the first axial direction, the second axial direction, and the third axial direction, and is driven by an actuator (not shown). After the drainage unit 33 moves from its original position to its set position, the pickling apparatus 60 detects the position of the supply / exhaust coupler 122, for example, by image recognition. After detection, the pickling apparatus 60 determines the amount of position correction in the first axial direction and the third axial direction. After the position correction operation is completed, the drainage nozzle 33 can move in the second axial direction to connect the drainage coupler 331 and the supply / exhaust coupler 112.

[0034] The cleaning liquid inside the hot water storage tank 10 is discharged to the liquid circulation unit 34 via the rotary valve 332. The liquid circulation unit 34 includes a tank 334 and a pump 335. Various cleaning liquids are stored in the tank 334. The pump 335 supplies the cleaning liquid stored in the tank 334 to the liquid injection nozzle unit 31. The liquid circulation unit 34 is responsible for circulating the cleaning liquid. The cleaning liquid is supplied from outside the casing 51, circulates through each part of the pickling apparatus 60, and then discharged outside the casing 51. This allows the treatment process to be transitioned without the hot water storage tank 10 floating.

[0035] In the liquid filling and draining device 30, when the rotary valve 312 is in the liquid filling state, the rotary valve 322 is in the exhaust state. Also, when the rotary valve 332 is in the liquid draining state, the rotary valve 322 is in the air supply state, pressurizing the inside of the hot water storage tank 10. This allows liquid to be filled and drained in a shorter time than the natural filling and draining that occurs with the conventional tank filling and draining operation.

[0036] A flow meter 333 is provided upstream of the tank 334, between the drain coupler 331 and the rotary valve 332. The flow meter 333 measures the amount of drainage from the hot water storage tank 10.

[0037] A pipe is connected from downstream of the rotary valve 332 to upstream of the rotary valve 312, passing through a tank 334, a pump 335, and a flow meter 336. The pipe is divided into three parts: system 1, system 2, and system 3. Water supplied from the outside to the liquid circulation unit 34 is connected to the tank 334 of system 1. Furthermore, drainage from the liquid circulation unit 34 to the outside is connected to the tanks 334 of system 1 and system 2.

[0038] A flow meter 336 is provided downstream of the pump 335 to measure the amount of liquid injected by the pump 335. In addition to the tank 334, pump 335, and flow meter 336, a gate valve, a rotary valve, and a flow meter are also provided at the positions shown in FIG.

[0039] The rolling device 20 described above further includes a load meter 204 that detects the actual weight, the amount of liquid actually poured, and the amount of liquid remaining in the hot water storage tank 10. As a result, leakage during liquid pouring is detected from the difference between the readings of the flow meter 336 and the load meter 204, and leakage during liquid drainage is detected from the difference between the readings of the flow meter 336 and the load meter 204.

[0040] The exhaust device 50 includes a casing 51 and an exhaust motor 52. The casing 51 encloses the hot water storage tank 10, the rolling device 20, and the liquid filling and draining device 30. The exhaust motor 52 locally exhausts air from inside the casing 51.

[0041] The exhaust from the exhaust motor 52 contains harmful substances such as nitric acid gas. Therefore, the exhaust device 50 includes an exhaust tower 53 that filters the exhaust from the exhaust motor 52. The exhaust filtered by the exhaust tower 53 is released into the atmosphere.

[0042] The control unit 500 includes a CPU (Central Processing Unit), a RAM (Random-Access Memory), etc., and controls the operation of each of the above-mentioned units. The control unit 500 may also include input means such as a keyboard and a mouse, and display means such as a display, in any configuration.

[0043] In addition, each section of the pickling device 60 is equipped with various measuring instruments including sensors, thermometers, and timers used in the pickling process, which will be described later.

[0044] 4 is a detailed diagram of the positioning device 40 according to the first embodiment of the present disclosure. Here, FIG. 4 shows the positioning state during liquid injection.

[0045] The positioning device 40 includes a lifting / lowering unit 41, an expandable unit 42, and a gripping unit 43. The lifting / lowering unit 41 is movable in a second axial direction. The expandable unit 42 is movable in a third axial direction.

[0046] The lifting / lowering unit 41 is raised and lowered by an actuator (not shown) along a movable shaft 44 in the second axial direction provided on the mounting plate 275. The lifting / lowering unit 41 extends in the third axial direction. An expandable unit 42 is attached to the tip of the lifting / lowering unit 41.

[0047] The lifting unit 41 can be positioned both when the liquid injection and drainage coupler 112 is facing upward along the third axis and when it is facing downward along the third axis. This allows the liquid injection and drainage coupler 112 and the liquid injection coupler 311 to be automatically connected when injecting liquid. In addition, it allows the liquid injection and drainage coupler 112 and the liquid drainage coupler 331 to be automatically connected when draining liquid.

[0048] The extension / contraction unit 42 extends in the third axis direction. The extension / contraction unit 42 is driven by an actuator (not shown) to horizontally extend and contract in the third axis direction. The horizontal extension / contraction movement is along a movable shaft 45 that is provided below the lifting / lowering unit 41 and extends in the third axis direction.

[0049] The extendable portion 42 has a gripping portion 43 at its tip. The gripping portion 43 is a mechanism that clamps the inlet / outlet coupler 112. The gripping portion 43 has a positioning block 401, a guide member 406, a lock lever 402, an actuator 404, and a floating mechanism 403.

[0050] The positioning block 401 is disposed movably in the first axial direction on the exhaust device 50 side of the expansion / contraction section 42. The positioning block 401 has a V-shaped groove for gripping the liquid injection / drainage coupler 112.

[0051] The guide member 406 is disposed on the surface of the extension / contraction section 42 on the side of the exhaust device 50. The guide member 406 guides the positioning block 401 in the first axial direction.

[0052] The lock lever 402 is formed in a long, thin plate shape and is supported rotatably around a second axis around a support portion 405 fixed to the extension / contraction portion 42.

[0053] One end of the actuator 404 is rotatably supported by the extension / contraction portion 42, and the other end is connected to an end of the lock lever 402. The other end of the actuator 404 extends and contracts relative to the one end. When the actuator 404 extends, the lock lever 402 extends in the first axial direction. As a result, as shown in FIG. 4( b), the gripping portion 43 grips the liquid injection / drainage coupler 112 with the positioning block 401 and the lock lever 402. When the actuator 404 contracts, the lock lever 402 extends in the third axial direction. As a result, the gripping portion 43 releases its grip on the liquid injection / drainage coupler 112.

[0054] The floating mechanism 403 absorbs manufacturing variations in the hot water storage tank 10 and variations in the installation position relative to the rolling device 20. The floating mechanism 403 is a pair of coil spring members that extend and expand in the first axial direction, sandwiching the positioning block 401. One end of each coil spring member is fixed to the positioning block 401, and the other end is fixed to the expansion / contraction portion 42. The expansion and contraction of the floating mechanism 403 causes the positioning block 401 to move flexibly. As a result, the gripping portion 43 grips the liquid injection / drainage coupler 112 while elastically supporting it in the first axial direction, thereby positioning the liquid injection / drainage coupler 112.

[0055] Next, an example of the pickling treatment of the hot water storage tank 10 will be described with reference to the flowcharts of FIGS.

[0056] The steps in the flowchart, an overview of the operations, and the main and other responsibilities are shown in Table 1. The symbols in the flowchart indicate the following: A1 and A2 are manual operations by workers. B1 to B3 are operations by the rolling device 20 and the positioning device 40. C1 and C2 are operations by the liquid injection and drainage device 30. D1 to D3 are operations by the exhaust device 50. Furthermore, the operations of each part other than those performed by humans are performed based on commands from the control unit 500 of the pickling equipment 60.

[0057]

[0058] When the pickling process starts (A1), the process proceeds to the loading operation shown in FIG. 5( a). In the loading operation, first, the worker loads the hot water storage tank 10 into the rolling device 20 (Step S1). Next, the worker checks whether the hot water storage tank 10 is present (Step S2). If the hot water storage tank 10 is present in the housing 271, the process proceeds to Step S3. If the hot water storage tank 10 is empty, the process returns to Step S1. Next, the worker sets the fall-off prevention mechanism 21 to the fall-off prevention enabled position (Step S3). Next, the worker checks the enabled position of the fall-off prevention mechanism 21 (Step S4). If the fall-off prevention mechanism 21 is in the enabled position, the process proceeds to Step S5. If the fall-off prevention mechanism 21 is in the disabled position, the process returns to Step S3. Next, the worker presses the operation button 274 on the rolling device 20 to close the safety door 273 (Step S5). Next, the worker checks whether the safety door 273 is locked (Step S6). If the safety door 273 is in the closed state, the process proceeds to the liquid injection positioning operation (B1) in Fig. 5B. If the safety door 273 is in the open state, the process returns to step S5.

[0059] In the liquid injection positioning operation, first, the rolling device 20 rolls the hot water storage tank 10 at a low speed (step S7). Next, it is confirmed whether the position of the boss 111 to which the liquid injection / drainage coupler 112 is attached corresponds to the position of the upper liquid injection coupler 311 (step S8). If the position is detected, the process proceeds to step S9. If the position is not detected and the hot water storage tank 10 continues to roll, the process returns to step S7. Note that although the term "boss position" is used in the flowchart, the position of the boss 111 and the position of the liquid injection / drainage coupler 112 in the rotational direction and the first axial direction are synonymous. Next, the rolling device 20 stops the rolling of the hot water storage tank 10 (step S9). Next, the positioning device 40 performs a positioning operation on the liquid injection / drainage coupler 112 (step S10). Next, the positioning device 40 confirms the positioning of the boss 111 (step S11). If it is in the valid position, the process proceeds to the liquid injection coupler connecting operation (C1) shown in Fig. 6(a), whereas if it is in the invalid position, the process returns to step S10.

[0060] In the liquid injection coupler connection operation, first, the liquid injection / drainage device 30 moves the liquid injection nozzle 31 from its original position to a set position corresponding to the liquid injection / drainage coupler 112 (step S12). Next, the liquid injection / drainage device 30 detects the position of the boss 111 (step S13). Next, the liquid injection / drainage device 30 performs a position correction operation for the liquid injection / drainage coupler 112 (step S14). Next, the liquid injection / drainage device 30 connects the liquid injection / drainage coupler 321 to the liquid injection / drainage coupler 122 and the liquid injection coupler 311 to the liquid injection / drainage coupler 112 (step S15). Next, the liquid injection / drainage device 30 checks the connections of the liquid injection / drainage coupler 321 and the liquid injection coupler 311 (step S16). If the connections are normal, the process proceeds to step S16a. If the connections are abnormal, the process returns to step S15. In step S16a, the liquid injection / drainage device 30 or the control unit 500 instructs the exhaust device 50 to start up. Thereafter, the process proceeds to step S17 and to a process (D1) in the exhaust device 50 shown in FIG. 6B.

[0061] In the liquid injection operation, first, the liquid injection and drainage device 30 switches the rotary valve 332 from closed to system n (step S17). Next, the liquid injection and drainage device 30 starts the pump 335 of system n to inject liquid into the hot water storage tank 10 (step S18). Next, the liquid injection and drainage device 30 detects liquid leakage (step S19). If no liquid leakage is detected and liquid injection continues, the process proceeds to step S20. If a liquid leakage is detected, the process proceeds to step S21. Next, the liquid injection and drainage device 30 detects the fixed amount of liquid (step S20). If the fixed amount is detected, the process proceeds to step S21. If the fixed amount is not detected and liquid injection continues, the process returns to step S18. Next, the liquid injection and drainage device 30 stops the tank 334 of system n to stop the liquid injection (step S21). Next, the liquid injection and drainage device 30 switches the rotary valve 332 from system n to closed (step S22).

[0062] Continuing from step S22, in the operation for disconnecting the injection coupler, first, the injection and drainage device 30 disconnects the coupler (step S23). The coupler disconnection is performed in the order of the injection coupler 311 to the supply and exhaust coupler 321. Next, the injection and drainage device 30 moves the injection nozzle part 31 from the current position to the original position (step S24). Thereafter, the process proceeds to the injection positioning release operation (B2) shown in FIG. 7.

[0063] In the process of the exhaust device 50 proceeding from step S16a, the exhaust device 50 is first started. After the exhaust device 50 is started, the gas concentration is measured (step S17a). Next, the exhaust device 50 checks whether the exhaust gas concentration is normal (step S19a). If the gas concentration is normal, the process proceeds to the carry-out operation (A2) shown in FIG. 9(c). If the gas concentration is abnormal, the process proceeds to step S21 in FIG. 6(a).

[0064] In the liquid injection positioning release operation, first, the positioning device 40 releases the position of the liquid injection / drainage coupler 112 (step S25). Next, the rolling device 20 confirms the positioning of the boss 111 (step S26). If the position is invalid, the process proceeds to step S27. If the position is valid, the process returns to step S25.

[0065] In the pickling treatment operation, first, the rolling device 20 performs the pickling treatment by rolling the hot water storage tank 10 (step S27). Next, the rolling device 20 checks whether the timer-set time has elapsed (step S28). If the set time has elapsed, the process proceeds to step S29. If the set time has not elapsed and the hot water storage tank 10 continues to roll, the process returns to step S27.

[0066] Continuing from step S28, in the drainage positioning operation, first, the rolling device 20 rolls the hot water storage tank 10 at a low speed (step S29). Next, the rolling device 20 detects whether the position of the boss 111 is below the drainage coupler 331 (step S30). If detected, the process proceeds to step S31. If the hot water storage tank 10 continues to roll, the process returns to step S29. Next, the rolling device 20 stops the rolling of the hot water storage tank 10 (step S31). Next, the positioning device 40 performs a positioning operation for the inlet / outlet coupler 112 (step S32). Next, the rolling device 20 confirms the positioning of the boss 111 (step S33). If the boss 111 is in the valid position, the process proceeds to the drainage coupler connecting operation (C2) shown in FIG. 8(a). If the boss 111 is in the invalid position, the process returns to step S32.

[0067] In the drainage coupler connection operation, first, the liquid injection / drainage device 30 moves the tip of the drainage section 33 from its original position to a set position corresponding to the liquid injection / drainage coupler 112 (step S34). Next, the liquid injection / drainage device 30 detects the position of the boss 111 (step S35). Next, the liquid injection / drainage device 30 performs a position correction operation for the liquid injection / drainage coupler 112 (step S36). Next, the liquid injection / drainage device 30 connects the liquid injection / drainage coupler 321 to the liquid injection / drainage coupler 122 and the liquid injection / drainage coupler 331 to the liquid injection / drainage coupler 112 (step S37). Next, the liquid injection / drainage device 30 checks the connections of the liquid injection / drainage coupler 321 and the liquid drainage coupler 331 (step S38). If the connections are normal, the process proceeds to step S38a. If the connections are abnormal, the process returns to step S37. In step S38a, the liquid injection / drainage device 30 or the control unit 500 instructs the exhaust device 50 to measure the gas concentration. Thereafter, the process proceeds to step S39 and to a process (D2) in the exhaust device 50 shown in FIG. 8B.

[0068] Continuing from step S38a, in the drainage operation, first, the liquid injection and drainage device 30 switches the rotary valve 332 from closed to open (step S39). Next, the liquid injection and drainage device 30 starts the pressurizing pump into the hot water storage tank 10 to drain the liquid (step S40). Next, the liquid injection and drainage device 30 detects liquid leakage (step S41). If liquid leakage is not detected, the process proceeds to step S42. If liquid leakage is detected, the process proceeds to step S43. Next, the liquid injection and drainage device 30 detects the fixed amount of liquid (step S42). If the fixed amount is detected, the process proceeds to step S43. If the fixed amount is not detected, the process returns to step S40. Next, the liquid injection and drainage device 30 stops the pressurizing pump to stop draining the liquid (step S43). Next, the liquid injection and drainage device 30 switches the rotary valve 332 from open to closed (step S44).

[0069] Continuing from step S44, in the drainage coupler disconnection operation, first, the liquid injection / drainage device 30 disconnects the couplers (step S45). The couplers are disconnected in the order of the supply / exhaust coupler 321 to the drainage coupler 331. Next, the liquid injection / drainage device 30 moves the drainage unit 33 from its current position to its original position (step S46). Thereafter, the process proceeds to the liquid drainage positioning release operation (B3) shown in FIG. 9(a).

[0070] In the process in the exhaust device 50 proceeding from step S38a, the exhaust device 50 first measures the exhaust gas concentration (step S41a). Next, the exhaust device 50 checks whether the exhaust gas concentration is normal (step S41b). If the gas concentration is normal, the process proceeds to the carry-out operation (A2) shown in FIG. 9C. If the gas concentration is abnormal, the process proceeds to step S43 in FIG. 8A.

[0071] In the operation for releasing the positioning during drainage, first, the positioning device 40 releases the position of the inlet / outlet coupler 112 (step S47). Next, the rolling device 20 checks the positioning of the boss 111 (step S48). If the position is invalid, the process proceeds to step S49. If the position is valid, the process returns to step S47.

[0072] In the process completion confirmation operation, the rolling device 20 confirms whether or not all processes have been completed (step S49). If the processes have been completed, the process proceeds to the gas concentration confirmation operation (D3) shown in Fig. 9(b). If the processes have not been completed, the process returns to step S7 shown in Fig. 5(b).

[0073] In the gas concentration confirmation operation, the exhaust device 50 checks whether the gas concentration is normal (step S50). If the gas concentration is normal, the exhaust device 50 performs a shutdown operation (step S50a), and the process proceeds to the carry-out operation (A2) shown in Fig. 9(c). If the gas concentration is abnormal, the process returns to step S43 in Fig. 8(a).

[0074] In the removal operation, first, the worker presses the operation button 274 of the rolling device 20 to open the safety door 273 (step S51). Next, the worker sets the fall-off prevention mechanism 21 to the fall-off prevention disabled position (step S52). Next, the worker removes the hot water storage tank 10 from the rolling device 20 (step S53). With these steps, the pickling treatment of the hot water storage tank 10 is completed.

[0075] With the configuration of the first embodiment, the workpieces are loaded into and unloaded from the pickling apparatus 60 when the hot water storage tank 10 is empty. In addition, the workpieces can be rocked without being filled with cleaning solution, but with a small amount of solution added, and the workpieces can be rocked without floating. Therefore, by adopting the first embodiment, a small-sized apparatus with low thrust can be realized.

[0076] Next, in the configuration of embodiment 1, the cleaning liquid reaches every detail of the inner surface of the workpiece. In addition, convection is generated in the cleaning liquid, which has the effect of homogenizing the concentration of the cleaning liquid and promoting the removal of scale. Furthermore, the liquid is injected by pump pressure and drained by air pressure, so that the liquid can be injected and drained in a short time. Therefore, by adopting embodiment 1, highly efficient cleaning can be achieved, which results in improved quality and takt time.

[0077] Furthermore, in the configuration of the first embodiment, no large immersion jig or large oscillating tilting device is interposed between the rolling roller 201 and the workpiece. This improves the horizontal accuracy of the workpiece, and reduces the amount of residual liquid inside the workpiece. In addition, as described above, highly efficient cleaning can be achieved, and therefore, washing can be performed with a small amount of water, particularly in the water rinsing process after pickling. Therefore, by adopting the first embodiment, it is possible to reduce the size and running costs of wastewater treatment equipment that reduces the concentration of high-concentration effluent discharged from the pickling apparatus 60 to the concentration level of industrial wastewater.

[0078] Furthermore, in the configuration of the first embodiment, the level of sealing is improved because the cleaning solution is injected into the workpiece. This, combined with the fact that the amount of solution injected is small, reduces the amount of nitric acid-based gases, particularly those emitted from the pickling solution. Therefore, by adopting the first embodiment, localized exhaust and reduced exhaust capacity can be achieved, enabling not only the device size but also the entire pickling facility to be miniaturized.

[0079] 10(a) to 10(c), in a rolling device 20, the hot water storage tank 10 is rolled via a rolling jig 25. The pickling apparatus 60 is the same as that of the first embodiment except for the following points. For example, a function equivalent to the liquid discharge section 277 is provided in the same manner as in the first embodiment.

[0080] The rolling jig 25 includes a frame 254 and two mounting portions 255. The frame 254 is formed in the shape of a rectangular frame. The mounting portions 255 are each a long, thin plate-like member. The mounting portions 255 extend parallel to the short sides of the rectangle and are fixed to the inside of the frame 254.

[0081] The rolling jig 25 further includes a non-driven rolling roller 251 , a guide roller 252 , and a conveyance positioning boss 253 .

[0082] The rolling roller 251 has four rolling elements attached to mounting portions 255. The rolling roller 251 supports the hot water storage tank 10 in the same manner as the rolling roller 201 in Fig. 2. The rolling roller 251 is rotated by a rolling drive unit 261, causing the hot water storage tank 10 to roll in place. The rolling drive unit 261 is connected to the rolling roller 251 after the hot water storage tank 10 and the rolling jig 25 are placed at the pickling treatment position within the housing 271.

[0083] The guide roller 252 includes four rolling elements attached to the short sides of the frame 254. The guide roller 252 guides the hot water storage tank 10 in the first axial direction while rolling, similar to the guide roller 202 in FIG.

[0084] The transport positioning boss 253 is provided on the lower part of the frame body 254. The transport positioning boss 253 has a hole that opens downward and is used to position the rolling jig 25.

[0085] 11(a) and (b) show a rolling device 20 according to embodiment 2. In this embodiment, a housing 271 is provided with an opening 272 on the front side where the operator is standing in FIG. 2, as well as an opening 280 on the rear side.

[0086] The rolling device 20 includes a transport conveyor 260 and a rolling drive unit 261 that pass through the housing 271 via the opening 272 and the opening 280 .

[0087] The transfer conveyor 260 passes through the housing 271 through the openings 272 and 280. The transfer conveyor 260 transfers the rolling jig 25 carrying the hot water storage tank 10 into the housing 271 or transfers it out of the housing 271. For example, the hot water storage tank 10 is placed or removed at a first position on the front side outside the housing 271, and the hot water storage tank 10 is subjected to an acid pickling treatment at a second position inside the housing 271. The transfer conveyor 260 transfers the rolling jig 25 between the first position and the second position.

[0088] When the hot water storage tank 10 is rolling, the safety doors 273 and 281 are attached to the openings 272 and 280. The safety doors 273 and 281 are provided with notches through which the transfer conveyor 260 passes.

[0089] The transport conveyor 260 includes a transport positioning device 264 and a lift-up prevention device 265 .

[0090] The transport positioning device 264 includes a positioning pin 282 and a movable shaft 283 in the second axial direction that raises and lowers the positioning pin 282. The transport positioning device 264 raises the positioning pin 282 and inserts it into the transport positioning boss 253, thereby improving the repeatability of stopping the rolling jig 25.

[0091] The lift-up prevention device 265 includes a pair of gripping members 284. The gripping members 284 are arranged near both ends of the rolling jig 25 in the first axial direction. Each of the gripping members 284 is formed in an L-shape by combining a portion that contacts the upper surface of the short side of the rolling jig 25 and a portion that suppresses movement of the rolling jig 25 in the first axial direction.

[0092] The lift-up prevention device 265 moves in the second axial direction and holds the rolling jig 25 vertically downward between the gripping member 284 and the transport conveyor 260. The vertically downward pressing force of the rolling drive unit 261 prevents the rolling jig 25 from lifting up and the rolling rollers 251 from spinning freely.

[0093] The rolling drive unit 261 rolls the hot water storage tank 10. The drive unit 261 moves in the second axial direction and brings the drive wheel 263 into contact with the rolling roller 251. The rolling drive unit 261 includes a drive motor 262 and a drive wheel 263 attached to the output shaft of the drive motor 262.

[0094] The drive motor 262 rotates the drive wheel 263. The drive wheel 263 is attached to the output shaft of the drive motor 262. The drive wheel 263 frictionally drives the rolling roller 251, causing the hot water storage tank 10 to roll.

[0095] According to the second embodiment, the loading and unloading of the hot water storage tank 10 can be automated using a transport conveyor without relying on workers, thereby improving productivity.

[0096] (Embodiment 3) In embodiment 3, as shown in Figures 12(a) and 12(b), the hot water storage tank 10 is rolled via a rolling cart 26. The rolling cart 26 is used in place of the combination of the rolling jig 25 and the roller table 276 in the rolling device 20 of embodiment 1. The pickling device 60 is the same as that of embodiment 1 except for the following points. For example, a function equivalent to the liquid discharge section 277 is provided as in embodiment 1. Furthermore, reference numerals that are the same as those in the previous embodiments indicate parts having the same function.

[0097] The rolling carriage 26 includes a carriage frame 256 , rolling rollers 251 , guide rollers 252 , and a conveyance positioning boss 257 .

[0098] The carriage frame 256 is configured as a frame of elongated members in the shape of a table with two legs.

[0099] Non-driven rolling rollers 251 and guide rollers 252 for rolling the hot water storage tank 10 are provided on the upper part of the bogie frame 256. The rolling roller 251 has four rolling elements attached to the bogie frame 256. The rolling roller 251 supports the hot water storage tank 10 in the same manner as the rolling roller 201 in Fig. 2. The guide roller 252 has four rolling elements attached to the short sides of the bogie frame 256. The guide roller 252 guides the hot water storage tank 10 in the first axial direction while it is rolling, in the same manner as the guide roller 202 in Fig. 2.

[0100] The transport positioning boss 257 is provided on the lower part of the leg of the rolling cart 26. The transport positioning boss 257 has a hole that opens downward and is used to position the rolling cart 26.

[0101] The rolling cart 26 further includes two drive running wheels 291, two driven running wheels 292, and a drive motor 293. The drive running wheels 291 and the driven running wheels 292 are provided on the lower part of the cart frame 256. The drive running wheels 291 are each attached to the output shaft of the drive motor 293 and rotate independently. The driven running wheels 292 rotate in response to the rotation of the drive running wheels 291. The rolling cart 26 carries the hot water storage tank 10 into and out of the pickling device 60 using the drive running wheels 291 and the driven running wheels 292.

[0102] 13(a) and (b) show a rolling device 20 according to a third embodiment. In this embodiment, a housing 271 is provided with an opening 272 on the front side where the worker is standing in FIG. 2, as well as an opening 280 on the rear side. The rolling cart 26 passes through the openings 272 and 280 during loading and unloading operations.

[0103] The rolling cart 26 carries the hot water storage tank 10 into the housing 271 or carries it out of the housing 271. For example, the hot water storage tank 10 is placed or removed at a first position on the front side outside the housing 271, and the hot water storage tank 10 is subjected to an acid pickling treatment at a second position inside the housing 271. The rolling cart 26 transports the hot water storage tank 10 between the first position and the second position.

[0104] The rolling carriage 26 further includes a rolling drive unit 261 and a transfer positioning device 294 .

[0105] The rolling drive unit 261 moves in the second axial direction, similarly to the second embodiment. The rolling drive unit 261 causes the drive wheels 263 to come into contact with the rolling rollers 251 to frictionally drive the hot water storage tank 10, thereby causing the hot water storage tank 10 to roll.

[0106] The transport positioning device 294 is fixed at two locations on the floor surface below the legs of the rolling cart 26. The transport positioning device 294 includes a transport positioning pin 295 and a movable shaft 296. The transport positioning device 294 improves the repeatability of stopping the rolling cart 26 by raising the transport positioning pin 295 and inserting it into the transport positioning boss 257.

[0107] According to the third embodiment, the hot water storage tank 10 is loaded and unloaded by the rolling cart 26, which travels independently without relying on an operator. This makes it possible to automate the loading and unloading of the hot water storage tank 10, improving productivity. Furthermore, the self-propelled rolling cart 26 eliminates the need for a fixed object such as a conveyor. This improves the flexibility of layout planning when multiple pickling devices 60 are installed due to process division or facility capacity expansion.

[0108] Although the present disclosure has been described above based on the embodiments, the present disclosure is not limited to the above-described embodiments and modifications, and various modifications and applications are possible.

[0109] The flow of the pickling treatment is not limited to that shown in the first embodiment, and additions, modifications, etc. may be made.

[0110] 4, the example in which the liquid inlet / outlet coupler 112 is gripped has been described. Alternatively, the boss 111 of the hot water storage tank 10 may be gripped.

[0111] In the second embodiment, the first position is the front side of the housing 271, but it may be the rear side of the housing 271. Also, a third position may be provided for another purpose.

[0112] In the third embodiment, the transport positioning pins 293 are disposed at the bottom of the carriage frame 256. Alternatively, they may be provided at a third position, such as on the top surface or side surface of the carriage.

[0113] In the third embodiment, the rolling rollers 251 are undriven and are driven by the rolling drive unit 261. Alternatively, the rolling carriage 26 may be provided with the rolling rollers having the drive described in the first embodiment.

[0114] The pickling apparatus described above is not limited to the above-described embodiment, and various modifications and substitutions can be made. Various embodiments of the present disclosure will be described below as appendices.

[0115] (Note) (Note 1) A pickling apparatus for performing a pickling treatment on a cylindrical hot water storage tank, comprising: a rolling roller that contacts a body of the hot water storage tank from below with the cylindrical central axis of the hot water storage tank lying horizontally, and rolls the hot water storage tank; a liquid injection and drainage device that injects and drains cleaning liquid into and discharges air from the hot water storage tank; and an exhaust device that prevents splashes of various cleaning liquids and scattering of generated gases.

[0116] (Supplementary Note 2) The pickling apparatus according to Supplementary Note 1, further comprising: a rolling jig to which the rolling rollers are attached; and a transport means for transporting the rolling jig between a first position where the hot water storage tank is placed or removed and a second position where the hot water storage tank is subjected to the pickling treatment.

[0117] (Supplementary Note 3) The pickling apparatus according to Supplementary Note 1, further comprising: a rolling cart on which the rolling rollers are attached; and a transport means for transporting the hot water storage tank between a first position where the hot water storage tank is placed or removed and a second position where the hot water storage tank is subjected to the pickling treatment.

[0118] (Supplementary Note 4) The pickling apparatus according to any one of Supplementary Notes 1 to 3, further comprising a positioning device that grips a boss for injecting and discharging liquid provided on the body of the hot water storage tank or a coupler attached to the boss while elastically supporting the boss, thereby positioning the injecting and discharging liquid.

[0119] (Supplementary Note 5) A method for pickling a hot water storage tank using the pickling apparatus and cleaning liquid according to any one of Supplementary Notes 1 to 4, comprising the steps of: carrying the hot water storage tank into the pickling apparatus; positioning the hot water storage tank for filling; pouring the cleaning liquid into the hot water storage tank; performing a pickling treatment on the hot water storage tank; and draining the cleaning liquid from the hot water storage tank, in this order; the positioning step comprises: rolling the hot water storage tank; and checking whether the position of the filling point of the hot water storage tank corresponds to an upper filling nozzle portion; and the draining step comprises pressurizing the hot water storage tank to drain the liquid.

[0120] The present invention allows various embodiments and modifications without departing from the broad spirit and scope of the present invention. Furthermore, the above-described embodiments are intended to explain the present invention and do not limit the scope of the present invention. That is, the scope of the present invention is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and the meaning of the invention equivalent thereto are considered to be within the scope of the present invention.

[0121] This application is based on Japanese Patent Application No. 2024-038450, filed on March 12, 2024. The entire specification, claims, and drawings of Japanese Patent Application No. 2024-038450 are incorporated herein by reference.

[0122] The present invention can be suitably employed, for example, in cleaning the hot water storage tank of a water heater.

[0123] 10 Hot water storage tank, 20 Rolling device, 21 Fall prevention mechanism, 25 Rolling jig, 26 Rolling cart, 30 Liquid injection and drainage device, 31 Liquid injection nozzle section, 32 Intake and exhaust section, 33 Liquid drainage nozzle section, 34 Liquid circulation section, 40 Positioning device, 41 Lifting section, 42 Telescopic section, 43 Grip section, 44 Movable shaft, 45 Movable shaft, 50 Exhaust device, 51 Casing, 52 Exhaust motor, 53 Exhaust tower, 60 Pickling device, 101 Shell, 102 Upper head plate, 103 Lower head plate, 111 Boss, 112 Liquid injection and drainage coupler, 121 Boss, 122 Intake and exhaust coupler, 201 Rolling roller, 202 Guide roller, 203 Movable shaft, 204 Load meter, 205 Drive mechanism, 211 Guide roller, 212 Movable shaft, 251 rolling roller, 252 guide roller, 253 conveyance positioning boss, 254 frame, 255 mounting portion, 256 carriage frame, 257 conveyance positioning boss, 260 conveyance conveyor (conveyance means), 261 rolling drive unit, 262 drive motor, 263 drive wheel, 264 conveyance positioning device, 265 lift-up prevention device, 271 housing, 272 opening, 273 safety door, 274 operation button, 275 mounting plate, 276 roller base, 277 liquid discharge portion, 278 air inlet, 279 exhaust port, 280 opening, 281 safety door, 282 positioning pin, 283 movable shaft, 284 gripping member, 291 drive running wheel, 292 driven running wheel, 293 drive motor, 294 conveyance positioning device, 295 Conveying positioning pin, 296 movable shaft, 311 liquid injection coupler, 312 rotary valve, 321 supply and exhaust coupler, 322 rotary valve, 331 liquid drain coupler, 332 rotary valve, 333 flow meter, 334 tank, 335 pump, 336 flow meter, 401 positioning block, 402 lock lever, 403 floating mechanism, 404 actuator, 405 support portion, 406 guide member, 500 control portion.

Claims

1. A pickling apparatus for performing pickling treatment on a cylindrical hot water storage tank, With the cylindrical central axis of the hot water storage tank lying horizontally, a rolling roller contacts the body of the hot water storage tank from below and causes the hot water storage tank to roll, The aforementioned hot water storage tank is equipped with a liquid injection / draining device that injects and drains cleaning solution and supplies and exhausts air, An exhaust system to prevent the scattering of droplets and gases from various cleaning solutions, The system includes a positioning device that elastically supports and grips a boss for pouring and draining liquid provided on the body of the hot water storage tank, or a coupler attached to the boss, in order to position the pouring and draining of liquid. Pickling equipment.

2. A rolling jig to which the aforementioned rolling rollers are attached, The system further comprises a conveying means for transporting the rolling jig between a first position for placing or removing the hot water storage tank and a second position for performing the pickling treatment on the hot water storage tank. The pickling apparatus according to claim 1.

3. A rolling carriage to which the aforementioned rolling rollers are attached, The system further includes a transport means for transporting the hot water storage tank between a first position for placing or removing the hot water storage tank and a second position for performing the pickling treatment on the hot water storage tank. The pickling apparatus according to claim 1.

4. A pickling apparatus for pickling a hot water storage tank, comprising: a rolling roller that contacts the body of the hot water storage tank from below and causes the hot water storage tank to roll when the cylindrical central axis of the hot water storage tank is laid horizontally; a liquid injection and discharge device that injects and discharges cleaning liquid and supplies and exhausts air to the hot water storage tank; and an exhaust device that prevents the scattering of various cleaning liquids and generated gases, and a method for pickling a hot water storage tank using the pickling apparatus and cleaning liquid, The steps include: transporting the hot water storage tank into the pickling apparatus; The steps include positioning the hot water storage tank when filling it with liquid, The steps include pouring the cleaning solution into the hot water storage tank, The steps include: performing an acid pickling treatment on the hot water storage tank, The steps include draining the cleaning solution from the hot water storage tank, Perform these steps in this order: The aforementioned positioning step is, The steps include: rolling the hot water storage tank, The method includes a step of confirming whether the position of the liquid injection point in the hot water storage tank corresponds to the position of the upper liquid injection nozzle, The aforementioned step of draining the liquid includes a step of pressurizing the hot water storage tank and draining the liquid, A method for pickling hot water storage tanks.