Automated Heat Exchanger Cleaning with Camera Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for washing heat exchanger bundles are inefficient due to manual operation, high detergent consumption, uneven cleaning, and inability to handle heat exchangers of varying sizes, leading to prolonged washing times and excessive water usage.
Innovation Solution
An automatic washing apparatus that uses a camera to recognize and map the position of heat exchanger tubes, allowing for precise control of internal and external washing modules, adjustable rotation, and reprocessing of washing water to reduce consumption and improve eco-friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual washing is performed by a worker, then the worker can directly control the washing process, but the worker has difficulty washing due to fine dust produced when detergent is sprayed and it takes long time to completely wash the tube
Solution Approach 1:
The patent replaces manual mechanical washing operations with an automated washing apparatus that uses a control unit to control washing machines. The system automatically sprays detergent and water through nozzles, eliminating the need for manual handling and significantly reducing washing time while avoiding exposure to fine dust.
Solution Approach 2:
The washing system is designed to perform washing operations autonomously without human intervention. The control unit automatically manages the washing process, including detergent injection, water spraying, and cycle timing, allowing the system to serve itself and eliminating manual labor concerns.
2Extent of automation
If air spray type washing apparatus is used, then washing can be automated, but it requires filling up a container with detergent and additionally injecting detergent because detergent is evaporated by production of bubbles, so too much detergent is consumed
Solution Approach 1:
The control unit monitors and manages detergent usage throughout the washing process, automatically adjusting injection amounts based on the specific washing requirements. This feedback-controlled approach prevents excessive detergent consumption by precisely dosing only what is needed, rather than continuous or excessive injection.
Solution Approach 2:
The system changes the physical state and delivery method of detergent from bubble-based air spray to direct liquid injection through nozzles. This parameter change eliminates detergent evaporation losses and allows precise control of detergent application, significantly reducing overall detergent consumption while maintaining automation.
3Extent of automation
If air spray type washing apparatus is used, then automation is achieved, but only the portions that the detergent comes in contact due to bubbles are washed, so uniform washing is difficult
Solution Approach 1:
The washing system divides the bundle into individual tubes and addresses each tube separately through controlled nozzle positioning. The control unit manages multiple washing machines that can independently treat different sections, ensuring uniform washing coverage across all tubes rather than relying on random bubble contact patterns.
Solution Approach 2:
The system replaces the random bubble-based detergent delivery with a controlled liquid spray system. Nozzles positioned at specific locations deliver detergent directly to tube surfaces through controlled spray patterns, ensuring uniform coverage. The control unit coordinates the timing and positioning of spray operations to achieve consistent washing results across all tubes.
4Ease of operation
If rotary devices are fixed at both ends to rotate heat exchanger tube, then rotation is achieved, but only heat exchangers with predetermined sizes can be washed
Solution Approach 1:
The system transitions from fixed rotary devices to a dynamic, adjustable positioning system. The washing machines and nozzles can be moved to different positions along the bundle length, and the rotation mechanism can accommodate various bundle sizes by adjusting its operational parameters. This dynamic adaptability allows the same apparatus to handle heat exchangers of different dimensions.
Solution Approach 2:
The washing apparatus is designed with multi-functional capabilities to handle various heat exchanger sizes. The control unit coordinates multiple washing machines that can be positioned at different locations, and the rotation system can accommodate different bundle dimensions. This universal design allows a single apparatus to serve multiple size requirements rather than requiring dedicated equipment for each size.
5Ease of operation
If fixed rotary devices are used, then rotation capability is provided, but a lot of washing water is consumed because it is impossible to selectively and precisely wash each tube
Solution Approach 1:
The system applies washing resources locally and selectively to specific tubes rather than uniformly to all tubes. The control unit manages multiple nozzles that can be positioned to target individual tubes or specific sections of the bundle. This localized approach ensures water and detergent are applied only where needed, significantly reducing overall consumption while maintaining effective washing of each tube.
Solution Approach 2:
The system replaces the water-intensive fixed rotary washing method with a controlled spray system. Nozzles deliver water and detergent in targeted spray patterns to specific tube surfaces, eliminating the need for excessive water flow required by rotary immersion methods. The control unit precisely manages spray timing and positioning to minimize water usage while achieving thorough washing.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An automatic washing apparatus for a heat exchanger is proposed. The automatic washing apparatus is configured to recognize positions of tube holes through a camera, and to automatically wash the tube holes. The automatic washing apparatus is also configured to be able to automatically wash an external bundle and internal tubes of a heat exchanger in accordance with set operation patterns of an external washing module and an internal washing module, and to be able to reuse washing water used for washing a heat exchanger as washing water by reprocessing the washing water.