Automated Heat Exchanger Tube Cleaning via Optical Positioning
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Solution Overview
Problem
The high-pressure cleaning of heat exchanger tubes is a tedious, tiring, and potentially hazardous task for operators due to manual positioning methods, which are dependent on visual inspection and prone to errors, especially in adverse conditions or when the exchanger moves during cleaning.
Innovation Solution
A method using a camera and lighting system arranged independently of the exchanger to automatically detect and align the cleaning device with the tubes, utilizing orthogonal markers and a calculator to determine an optimal cleaning path, allowing for remote visualization and reduced operator risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual positioning with naked eye is used, then the operator can directly see the result of positioning actions, but the positioning is too slow and random, and the operator must be within 5m distance which exposes them to contaminated water mist
Solution Approach 1:
An optical system with camera and orthogonal markers acts as an intermediary between the operator and the cleaning device. The camera captures images of the support plate and cleaning device positions, which are then processed to calculate precise positioning data. This allows the operator to remain at a safe distance (>5m) while still achieving accurate positioning through the intermediary visual feedback system.
Solution Approach 2:
The manual visual positioning method is replaced with an optical measurement system. Instead of relying on the operator's naked eye and manual judgment, the system uses a camera to capture images, processes these images to detect orthogonal markers, and calculates positions automatically. This substitution eliminates the need for the operator to be close to the contaminated area while improving positioning precision.
2Measurement precision
If the operator positions themselves close to the exchanger (1-5m) to visualize the cleaning result, then they can see the positioning accuracy, but they are exposed to contaminated water mist and hydrocarbons
Solution Approach 1:
The optical system serves as a mediator that transfers visual information from the cleaning area to the operator's location. The camera positioned on the mobile support captures images of the support plate and cleaning device, and these images are processed to provide positioning feedback. This allows the operator to visualize positioning accuracy remotely without being exposed to the contaminated environment.
Solution Approach 2:
The system creates a visual copy of the cleaning area through camera imaging. Instead of directly observing the actual cleaning process up close, the operator views processed images that replicate the visual information needed for positioning. This copying mechanism enables safe remote operation while maintaining visualization capability.
3Productivity
If high-pressure water jets are used for cleaning, then the cleaning effectiveness is high, but the exchanger may move or recoil suddenly, adding safety risks
Solution Approach 1:
The system continuously monitors the position of the cleaning device relative to the support plate using the optical system. By capturing images before, during, and after cleaning operations, the system can detect any movements of the exchanger or cleaning device. This feedback mechanism allows for real-time position correction and safety monitoring, enabling the use of high-pressure jets while maintaining stability control.
Solution Approach 2:
The system performs preliminary positioning and alignment using the optical measurement system before initiating high-pressure cleaning. The orthogonal markers and image processing establish a precise reference framework in advance, allowing the cleaning device to be accurately positioned. This preliminary setup ensures that when high-pressure jets are applied, the system is ready to detect and respond to any movements through continuous monitoring.
4Stability of the object's composition
If the cleaning device is connected to the exchanger, then positioning stability is improved, but flexible rails are required which increases device complexity
Solution Approach 1:
The mechanical connection system (flexible rails) is replaced with an optical measurement and control system. Instead of physically connecting the cleaning device to the exchanger through complex flexible rail mechanisms, the system uses image capture and processing to establish positional relationships. The orthogonal markers provide a reference framework that enables stable positioning control without physical mechanical connections, thereby reducing device complexity.
Data Source
AI summary
Some embodiments are directed to a method for guiding a high-pressure cleaning device for cleaning the inside of heat exchanger tubes, wherein the human eye has been replaced by an acquisition device, enabling to obtain images, making the automatic detection of tubes to be cleaned possible, with the possibility of remote visualization.