UHPWJ Hydro-blasting Robot with Cyclone Separator
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Solution Overview
Problem
Current cleaning systems for large, complex, or hard-to-reach surfaces like penstocks are labor-intensive, hazardous, and inefficient, particularly in removing rust and old coatings, and lack effective automation for surface preparation and coating application, posing safety risks and high operational costs.
Innovation Solution
An autonomous Ultra-High-Pressure Water Jetting (UHPWJ) hydro-blasting/cleaning system with a mobile robot equipped with a rotating cleaning head and cyclone separator for efficient dust removal and waste management, allowing for remote operation and reduced on-site intervention, featuring a closed loop system that minimizes particle emission and operator risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual surface preparation methods are used, then operators can perform cleaning and coating removal, but the process becomes labor-intensive, hazardous, and time-consuming
Solution Approach 1:
The system performs surface preparation autonomously through a mobile robot that navigates, cleans, and prepares surfaces without continuous human intervention. The robot equips itself with appropriate tools (water jetting, abrasive blasting, or sanding) based on the detected surface condition, enabling self-service operation.
Solution Approach 2:
The mobile robot is designed as a multi-functional platform that can perform multiple surface preparation tasks including water jetting, abrasive blasting, and sanding operations. This universal design allows a single device to replace multiple specialized tools and manual processes.
2Adaptability or versatility
If traditional cleaning systems are used, then simple surfaces can be cleaned, but large, complex, or hard-to-reach surfaces cannot be effectively treated
Solution Approach 1:
The mobile robot features dynamic adaptability through adjustable cleaning parameters (pressure, flow rate, abrasive type) and movable components that can accommodate different surface geometries. The system dynamically adjusts its operation based on real-time feedback from surface condition detection.
Solution Approach 2:
The cleaning system is divided into modular functional units (water jetting module, abrasive blasting module, sanding module, detection system) that can be independently selected and configured based on the specific surface requirements, enabling versatile application across different geometries.
3Productivity
If high-pressure water jetting is used, then effective rust and coating removal is achieved, but water and waste dispersion causes environmental contamination
Solution Approach 1:
The system converts the potentially harmful dispersed water and waste into a controlled benefit by using the high-velocity water jet to both clean the surface and simultaneously capture the waste material. The same water flow that removes rust and coating also transports the debris into collection containers, turning a contamination problem into an integrated cleaning-and-collection solution.
Solution Approach 2:
The high-velocity water jet acts as an intermediary medium that performs dual functions: it removes contaminants from the surface while also serving as the transport mechanism for waste removal. The water flow mediates between the cleaning action and waste collection, eliminating the need for separate disposal systems.
4Reliability
If scaffolding and containment structures are erected, then operator safety is improved, but the process becomes time-consuming and costly
Solution Approach 1:
The system replaces the mechanical scaffolding and containment structures with an autonomous mobile robot that inherently maintains safety through automated operation. The robot performs all hazardous surface preparation tasks without requiring human operators to be positioned on scaffolds or near containment areas, eliminating the need for these supporting structures.
Solution Approach 2:
The robot autonomously navigates and positions itself on the surface to be cleaned, eliminating the need for manual scaffolding erection. The system self-manages the entire cleaning process from approach to completion without requiring external support structures or containment setups.
5Manufacturing precision
If multiple specialized equipment are deployed for different cleaning tasks, then specific surface requirements are met, but transportation and handling costs increase
Solution Approach 1:
The mobile robot is designed as a universal platform that integrates multiple cleaning functions (water jetting, abrasive blasting, sanding) into a single device. This multi-functionality allows the system to meet various surface preparation requirements while eliminating the need for multiple separate specialized equipment pieces.
Solution Approach 2:
The system merges previously separate cleaning technologies (high-pressure water jetting, abrasive blasting equipment, sanding machines) into a single integrated mobile robot platform. This consolidation combines multiple functions into one device, reducing the total number of equipment components and simplifying deployment.
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 enables efficient, automated surface preparation and coating application on large, complex surfaces with reduced operational time, safety risks, and transportation costs, while ensuring compliance with safety standards and environmental protection.
Implementation Method 1
a UHP cleaning head with a shell forming a bell adapted to confine the projected water and to capture, at source, the waste hydro-blasted/scoured by the projected water on the surface
Implementation Method 2
a suction tank accommodating a cyclone separator adapted to separate the water containing the hydro-blasted/scoured waste from air
Implementation Method 3
a vacuum suction device, connected to one of the fluidic outlet of the suction tank such, in order to suck the water containing the waste hydro-blasted/scoured inside the bell
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
The present invention concerns a Ultra-High Pressure Water Jetting (UHPWJ) hydro-blasting/cleaning system (1) for surfaces (P) of very large dimensions and/or complex shapes and/or difficult access and/or with a high elevation. The UHPW system includes a rotating cleaning head (4) which can be kept in contact with the surface to be hydro-blasted/cleaned and sucking means which are judiciously physically separated, i.e. a cyclone type device (5) which is mounted on the mobile robot (2) and therefore can separate the gas phase from the liquid and solid phases, very near to the hydro-blasting/cleaning head, while minimizing the flow pressure drop, and a vacuum suction device (6) that is placed up to a significant distance from the cleaning head and generates the depression that drives the three-phase mixture into the cyclone.