Spatial Layout Optimization of Ultra-high-pressure Water Jet Self-driven Rotary Sprayer

doi:10.3969/j.issn.1004-132X.2026.03.012

Abstract

Abstract:

To enhance the hydrodynamic performance and rust-removal efficiency of the UHP water jet rotary sprayers， a novel layout optimization strategy was proposed based on the PSO algorithm. The sweep impinging trajectory， accumulative impinging-duration， and self-rotary models were successively established based on a fully motion characteristics analysis of the rotary sprayers. The self-rotary model revealed the influences of nozzle spatial layout on rotational speed and provided a theoretical basis for determining the attack angle. By regarding the uniformity of water jet impinging energy distribution and the sweep impinging width as evaluation criteria， a bi-objective optimization model was established. Then， the optimal spatial layouts of the nozzles were obtained via PSO algorithm， and the corresponding attack angles were derived from the self-rotary model. Finally， an actual optimization experiment was conducted using a rod-like shape 16-nozzle rotary sprayer commonly adopted in a shipyard of Zhejiang. Results show that the optimized design improves the uniformity of sweep impinging energy distribution by 22.81% and increases rust-removal efficiency by approximately 11.2%.

Key words: ultra-high-pressure （UHP）, impinging jet, layout optimization, rust-removal efficiency, particle swarm optimization （PSO）algorithm

摘要：

为提高超高压水射流旋转喷头水动力性能与除锈效率，提出了一种基于粒子群优化算法的布局优化策略。通过分析旋转喷头的运动特征，建立了扫掠冲击轨迹模型、累计冲击持续时间模型和自驱旋转模型，其中，自驱旋转模型揭示了喷嘴布局对自旋转速度的影响，并为冲击角设定提供理论依据。以水射流能量分布均匀性和扫掠冲击宽度为衡量标准，构建了双目标优化模型，并采用粒子群优化算法求解最佳喷嘴空间布局；结合自驱旋转模型确定对应冲击角参数。最后，以浙江修造船企业常用的“一”字形16喷嘴旋转喷头为例，进行了实际优化试验，结果表明，经优化后喷头的扫掠冲击能量分布均匀度较原设计提高了22.81%，除锈效率提高了约11.2%。

关键词: 超高压, 冲击射流, 布局优化, 除锈效率, 粒子群优化算法

CLC Number:

O358

ZHAO Wentao, CHEN Zhengshou, CHEN Yuanjie, DU Bingxin, TAN Xiaoli. Spatial Layout Optimization of Ultra-high-pressure Water Jet Self-driven Rotary Sprayer[J]. China Mechanical Engineering, 2026, 37(3): 624-633.

赵文涛, 陈正寿, 陈源捷, 杜炳鑫, 谭小利. 超高压水射流自驱旋转喷头空间布局优化[J]. 中国机械工程, 2026, 37(3): 624-633.

Figures/Tables 16

Fig.1 Structure of self-driven rotary sprayer

Fig.2 Structure of straight-cone convergent nozzle［16］

Fig.3 Working diagram of rotary sprayer

Fig.4 Sweep motion model of single nozzle

Fig.5 The accumulative impinging-duration model

Fig.6 Design workflow for the rotary sprayer

Fig.7 Comparison of the spatial layouts and attack angles of the unoptimized and PSO-optimized rotary sprayers

Fig.8 Comparison of the sweep impinging trajectories of the unoptimized and PSO-optimized rotary sprayers

Fig.9 Comparison of the accumulative impinging durations for unoptimized and PSO-optimized rotary sprayers

Fig.10 Comparison of the relative distributions of accumulative impinging durations for unoptimized and PSO-optimized rotary sprayers

Fig.11 Variation in rotational speed under different pressures for PSO-optimized rotary sprayer

Fig.12 Experimental test snapshot of the rotary de-rusting sprayer device using a wall-climbing carrier platform

Fig.13 Assembly diagram of speed testing system via ultra-high-pressure water jet

Fig.14 Ultra-high-pressure plunger pump system

Fig.15 Rotation-speed measurement system

Fig.16 Theoretical and experimental comparison of rotation speeds

References 24

[1]	衣正尧，弓永军，王祖温，等. 用于搭载船舶除锈清洗器的大型爬壁机器人［J］. 机器人， 2010， 32（4）： 560-567.
	YI Zhengyao， GONG Yongjun， WANG Zuwen， et al. Large Wall Climbing Robots for Boarding Ship Rust Removal Cleaner［J］. Robot， 2010， 32（4）： 560-567.
[2]	沈娟. 高压水射流喷嘴的设计及其结构优化［D］. 苏州：苏州大学， 2014.
	SHEN Juan. High Pressure Water Jet Nozzle Design and Structural Optimization［D］. Suzhou：Suzhou University， 2014.
[3]	HUANG L Y， CHEN Z S. Effect of Technological Parameters on Hydrodynamic Performance of Ultra-high-pressure Water-jet Nozzle［J］. Applied Ocean Research， 2022， 129： 103410.
[4]	ZHAO W T， CHEN Z S， DU B X， et al. CFD Analysis on Hydrodynamic Characteristics of Ultra-high-pressure Water Jets： Stationary vs. Translating Nozzle Conditions［J］. Engineering Applications of Computational Fluid Mechanics， 2025， 19（1）： 2552894.
[5]	CHEN Y， CHEN Z. A Prediction Model of Wall Shear Stress for Ultra-high-pressure Water-jet Nozzle Based on Hybrid BP Neural Network［J］. Engineering Applications of Computational Fluid Mechanics， 2022， 16（1）： 1902-1920.
[6]	NI L X， CHEN Z S， LIU Z， et al. Hydrodynamic Analysis of Ultra-high Pressure Water Derusting Nozzle ［C］∥ Proceedings of the ISOPE International Ocean and Polar Engineering Conference. Shanghai， 2020： ISOPE-I-20- 3119.
[7]	HANSON B R， ORLOFF S B. Rotator Nozzles More Uniform than Spray Nozzles on Center-pivot Sprinklers［J］. California Agriculture， 1996， 50（1）： 32-35.
[8]	LI H， JIANG Y， XU M， et al. Effect on Hydraulic Performance of Low-pressure Sprinkler by an Intermittent Water Dispersion Device［J］. Transactions of the ASABE， 2016， 59（2）： 521-532.
[9]	HUANG J， ZENG J， BAI Y， et al. Layout Optimization of Fiber Bragg Grating Strain Sensor Network Based on Modified Artificial Fish Swarm Algorithm［J］. Optical Fiber Technology， 2021， 65： 102583.
[10]	JIN S， JIA Y， WEI J. A Method about Antenna Layout Optimization on Particle Swarm Optimization［C］∥ Proceedings of the 2015 IEEE 6th International Symposium on Microwave， Antenna， Propagation， and EMC Technologies （MAPE）. Shanghai， 2015： 400-404.
[11]	RIZK-ALLAH R M， HASSANIEN A E. A Hybrid Equilibrium Algorithm and Pattern Search Technique for Wind Farm Layout Optimization Problem［J］. ISA Transactions， 2023， 132： 402-418.
[12]	时光辉，贾宜播，郝文宇，等. 基于数据驱动的舵面结构优化设计［J］. 力学学报， 2023， 55（11）： 2577-2587.
	SHI Guanghui， JIA Yibo， HAO Wenyu， et al. Optimal Design of Rudder Structures Based on Data-driven Method［J］. Chinese Journal of Theoretical and Applied Mechanics， 2023， 55（11）： 2577-2587.
[13]	陈源捷，陈正寿，杜炳鑫，等. 基于ESGA遗传算法的水射流自驱旋转喷头优化设计［J］. 爆炸与冲击， 2023， 43（2）： 130-143.
	CHEN Yuanjie， CHEN Zhengshou， DU Bingxin， et al. Optimum Design of Self-driven Rotary Water-jet Sprayer Based on ESGA Genetic Algorithm［J］. Explosion and Shock Waves， 2023， 43（2）： 130-143.
[14]	宋寒冬，陈正寿，杜炳鑫，等. 基于改进秃鹰算法的自旋转水射流喷头布局优化方法［J］. 计算机集成制造系统， 2025， 31（9）： 3485-3500.
	SONG Handong， CHEN Zhengshou， DU Bingxin， et al. Layout Optimization Method of Self-driven Water-jet Rotating Sprinkler Based on Improved Bald Eagle Search Algorithm［J］. Computer Integrated Manufacturing Systems， 2025， 31（9）： 3485-3500.
[15]	CHEN Z， ZHAO W， LI J， et al. An Advanced Framework for the Layout Optimization of Multi-nozzle Rotary Derusting Sprayer Using CFD-IBES Methods［J］. Applied Ocean Research， 2025， 161： 104662.
[16]	ZHAO W， CHEN Z， CHEN Y， et al. Chamber Shape Optimization for Ultra-high-pressure Water-jet Nozzle Based on Computational Fluid Dynamics Method and a Data-driven Surrogate Model［J］. Engineering Applications of Computational Fluid Mechanics， 2025， 19： 2443128.
[17]	薛胜雄，王乐勤，彭浩军，等. 超高压水射流除锈机理试验研究［J］. 中国机械工程， 2004， 15（20）： 1790-1793.
	XUE Shengxiong WANG Leqin， PENG Haojun， et al. Experimental Research on Mechanism of Ultrahigh Pressure Waterjet De-rusting［J］. China Mechanical Engineering， 2004， 15（20）： 1790-1793.
[18]	龙明庆. 双喷咀旋转速度的理论计算公式［J］. 高压水射流， 1990（1）： 18-19.
	LONG Mingqing. Theoretical Calculation Formula for Rotational Speed of a Dual-nozzle System［J］. High Pressure Water Jetting， 1990（1）： 18-19.
[19]	CHEN Y， CHEN Z， ZHAO W， et al. Optimisation Strategy to Enhance the Performance and Efficiency of Self-rotary Water-jet Derusting Sprayers［J］. Ocean Engineering， 2024， 303： 117620.
[20]	ZHANG A， SUN P， MING F， et al. Smoothed Particle Hydrodynamics and Its Applications in Fluid-structure Interactions［J］. Journal of Hydrodynamics， Ser B， 2017， 29（2）： 187-216.
[21]	孙玲，弓永军，王祖温，等. 超高压旋转清洗盘的设计及密封分析［J］. 中国机械工程， 2014， 25（13）： 1715-1718.
	SUN Ling， GONG Yongjun， WANG Zuwen， et al. Design and Sealing Analysis of Ultr-high Pressure Water Cleaning Rotary Device［J］. China Mechanical Engineering， 2014， 25（13）： 1715-1718.
[22]	GUO P， ZHAO Z， ZHANG Y， et al. Adaptive Access Strategy for Satellite-terrestrial Optical Networks Based on Particle Swarm Optimization Algorithm［J］. Physical Communication， 2025， 69： 102600.
[23]	STOPPATO A， CAVAZZINI G， ARDIZZON G， et al. A PSO （Particle Swarm Optimization）-based Model for the Optimal Management of a Small PV（Photovoltaic）- pump Hydro Energy Storage in a Rural Dry Area［J］. Energy， 2014， 76： 168-174.
[24]	SHI Y， EBERHART R. A Modified Particle Swarm Optimizer［C］∥ Proceedings of the 1998 IEEE International Conference on Evolutionary Computation. Anchorage， AK， 1998： 69-73.