Remote Excavator Hydroblasting System for Confined Space Cleaning
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Solution Overview
Problem
Current methods for cleaning industrial process equipment with high-pressure lances are hazardous, inefficient, and require significant physical effort, leading to operator fatigue and increased costs due to the need for manual operation and protective gear, with limited precision and restricted use to large outdoor areas.
Innovation Solution
A compact excavating tractor is converted into a remotely operated, computer-controlled high-pressure wash system using electrohydraulic valves and a computer control station, allowing precise control of the articulating arm and spray head from a safe distance, reducing operator exposure and enabling efficient cleaning in smaller spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a handheld high-pressure lance is used for cleaning, then cleaning effectiveness is improved, but operator safety deteriorates due to exposure to blowback and hazardous environments
Solution Approach 1:
A remotely operated vehicle serves as an intermediary between the operator and the cleaning process. The vehicle carries the high-pressure lance and positioning system, allowing the operator to control cleaning from a safe distance while the vehicle navigates close to the equipment being cleaned, thus mediating the harmful proximity exposure
Solution Approach 2:
Manual mechanical control of the lance is replaced with automated robotic control systems. The vehicle is equipped with sensors, actuators, and control algorithms that automatically position and maneuver the lance, replacing the operator's direct mechanical handling and eliminating their exposure to hazardous conditions
2Ease of operation
If manual operation of high-pressure lance is used, then flexibility in cleaning is improved, but operator fatigue increases due to physical exertion
Solution Approach 1:
The robotic vehicle performs self-navigation and self-positioning using onboard sensors and actuators. The system autonomously maneuvers the articulating arm and lance to maintain optimal cleaning positions, eliminating the need for continuous manual physical adjustment and reducing operator fatigue while preserving cleaning flexibility through programmable control
Solution Approach 2:
Sensors on the vehicle provide real-time feedback on position, orientation, and cleaning effectiveness. This feedback is processed by control algorithms that automatically adjust the lance positioning and movement, enabling flexible adaptation to different cleaning scenarios without requiring continuous manual intervention and reducing operator physical exertion
3Productivity
If large tractors are used for cleaning operations, then cleaning capability is improved, but adaptability to different environments deteriorates due to size constraints
Solution Approach 1:
The cleaning system is segmented into modular components: a compact base vehicle, an articulating arm assembly, and a lance module. This segmentation allows the system to maintain high cleaning capability through the articulating arm's range of motion while keeping the base vehicle small enough to navigate confined spaces and complex equipment geometries that large tractors cannot access
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances safety and efficiency by eliminating operator fatigue, reducing the need for protective gear, and allowing precise control of the cleaning process, enabling effective cleaning of complex equipment in various environments without the limitations of manual operation.
Implementation Method 1
direct a stream of high pressure cleaning solution, typically water, at close range against the process equipment to be cleaned
Implementation Method 2
electrohydraulic valves that in turn controls the mechanical movements of the articulating arm and an attached high pressure spray head
Data Source
AI summary
A process for the manufacture of a washing system to clean process equipment and the resulted washing system is disclosed. The method involves the conversion and transformation of a small excavation tractor into a remotely operated hydroblasting system that removes the operator from the working environment and avoids the risks of harm and fatigue normally associated with existing cleaning processes.