Tube Bundle Cleaning Device with Depth Documentation
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Solution Overview
Problem
Existing methods for cleaning tube bundles in heat exchangers and similar applications are labor-intensive, prone to operator errors, and do not reliably ensure all tubes are cleaned, with manual processes exposing operators to hazards and requiring extensive assembly and alignment of complex components.
Innovation Solution
A method and device that measure and document the insertion depth of a rotating cleaning lance into each tube, creating a three-dimensional cleaning profile to ensure complete cleaning, with semi- or fully automated operation, and a system to monitor and control the cleaning process, reducing manual intervention and operator exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cleaning by operator is used, then flexibility and adaptability are maintained, but operator safety is compromised and cleaning completeness cannot be guaranteed
Solution Approach 1:
A remotely operable control unit serves as an intermediary between the operator and the cleaning device. The control unit includes a video camera and lamps that transmit real-time images to the operator, allowing remote monitoring and control of the cleaning process. This eliminates direct operator exposure to hazardous environments while maintaining operational flexibility through remote intervention.
Solution Approach 2:
The patent replaces manual mechanical cleaning operations with an automated high-pressure hose system that can be remotely controlled. The mechanical cleaning action is performed by the automated device rather than direct human intervention, substituting the operator's physical presence with a remotely controlled mechanical system that eliminates safety hazards while maintaining cleaning effectiveness.
2Object-affected harmful factors
If remote control with video camera is used, then operator safety is improved, but operator error remains possible and cleaning completeness cannot be guaranteed
Solution Approach 1:
The control unit incorporates a video camera that provides real-time visual feedback to the operator during the cleaning process. This feedback mechanism allows the operator to monitor the cleaning progress and verify that all pipes are being cleaned, enabling immediate correction of any omissions or errors and ensuring complete cleaning coverage.
Solution Approach 2:
The system performs preliminary documentation of the cleaning process through video recording and data logging. By recording the cleaning sequence and results beforehand, the system creates a verifiable record that can be reviewed to ensure all pipes were cleaned, preventing omissions and enabling accountability for cleaning completeness.
3Extent of automation
If XY displacement mechanism with multiple stands is used, then automated cleaning is achieved, but device complexity and assembly requirements increase significantly
Solution Approach 1:
The patent extracts and eliminates the complex XY displacement mechanism, multiple stands, and rail systems from the cleaning device. By removing these unnecessary mechanical components, the invention achieves automated cleaning through a simplified single-hose system that can be remotely controlled, dramatically reducing assembly complexity while maintaining automation benefits.
Solution Approach 2:
The simplified cleaning device is designed as a universal system that can clean various pipe configurations without requiring complex mechanical adaptation. The remote control unit and high-pressure hose system can be applied to different pipe layouts and orientations, eliminating the need for multiple specialized stands and displacement mechanisms while maintaining automated cleaning capability.
4Manufacturing precision
If precise alignment of components is required, then cleaning effectiveness is improved, but assembly time and operational complexity increase
Solution Approach 1:
The invention adopts a disposable or easily replaceable high-pressure hose system that eliminates the need for precise alignment of permanent mechanical components. The hose can be quickly connected and disconnected without requiring complex alignment procedures, dramatically reducing assembly time while maintaining cleaning effectiveness through the flexibility of the hose system.
Solution Approach 2:
The system transitions from rigid mechanical components requiring precise alignment to a flexible hose-based system where alignment is achieved through positional parameters rather than mechanical precision. The hose can accommodate various positions and angles, eliminating the need for exact component alignment while maintaining cleaning effectiveness through adjustable positioning.
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 method and device ensure thorough and efficient cleaning of tube bundles, reducing cleaning time and operator risk, while providing detailed contamination data for post-cleaning analysis, allowing for immediate re-cleaning of partially cleaned tubes and reducing the need for extensive manual assembly.
Implementation Method 1
A high-pressure hose, equipped with a spray nozzle at its front end, is then pushed through the individual pipes, so that high-pressure cleaning fluid, especially water, sprays from the nozzle and removes the deposits from the inner walls of the pipes
Data Source
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AI summary
The invention relates to a method and to a cleaning device (10) for cleaning tubes (4) of tube bundles (1), wherein at least one rotating cleaning lance (14) is used. During the insertion of the cleaning lance (14), the insertion depth E of the cleaning lance is measured and is stored and documented in a storage and documentation device (102). The cleaning device (10) has an XY displacement device (30), on which a support rail (40) is arranged, which supports a cleaning apparatus (12).