Fully automatic modular large diameter light-cured pipe repair material laying and conveying device

Abstract

The application discloses a kind of full-automatic modularization large-diameter photocuring pipeline repair material laying conveying equipment, including laying conveying equipment, the laying conveying equipment is composed of controller unit and multiple power conveying units, each power conveying unit is composed of support, roller group, large torque servo motor and sensor comprehensive unit, the multiple power conveying units are connected by hand-in-hand composite cable, and the control interface of first-stage power conveying unit is electrically connected with controller unit by composite cable, and connecting bracket is arranged between the power conveying units, compared with prior art, the laying conveying equipment of the application adopts modularization design, and the power conveying unit can be increased or decreased arbitrarily according to the length of pipeline, and is very flexible in deployment, each module is miniaturized and lightened relative to the overall equipment, and is simple and fast in deployment, is more labor-saving for heavy pipe conveying, greatly reduces the working intensity of workers, reduces the number of on-site workers, and saves construction cost.

Description

Technical Field

[0001] This invention relates to the field of municipal pipeline repair, and in particular to a fully automatic modular large-diameter light-cured pipeline repair material laying and conveying equipment. Background Technology

[0002] In the process of repairing defects in municipal drainage pipe networks, trenchless UV-cured pipe lining repair technology is used. This involves attaching a layer of UV-cured material to the inner wall of the existing pipe to achieve the repair purpose. During the repair process, the entire UV-cured pipe needs to be dragged into the cleaned existing pipe to be repaired. Currently, in the construction process, for small-diameter UV-cured pipe repair materials, a PTFE-based sliding mulch is laid on the ground, and the small-diameter UV-cured pipe is placed on the sliding mulch to allow the UV-cured pipe to be dragged on the ground. For slightly larger-sized UV-cured pipes, some non-powered roller supports are used to change sliding friction to rolling friction, thereby solving the problem of dragging the UV-cured pipe.

[0003] Although auxiliary technologies such as sliding mulch and roller supports were used on-site, the dragging process of UV-cured pipes was still significantly hampered by the pipe's diameter and length. For large (extra-large) diameter pipes (600mm and above) with lengths exceeding 5m, construction presented substantial challenges. Larger diameter and thicker wall thickness of the UV-cured pipe resulted in greater weight per unit length; the longer the pipe, the heavier it was, leading to greater frictional forces during dragging. Therefore, dragging large-diameter UV-cured pipes on-site was extremely difficult, often requiring extensive manual labor and demanding high levels of coordination and physical exertion from workers. Furthermore, the flexible nature of UV-cured pipes, which need to bend according to the municipal pipeline route, meant that some municipal pipelines, reaching tens of meters in length, were not only too heavy to drag but also prone to localized bending and arching, posing significant obstacles to dragging. Constructing large conveyor equipment on-site would not only result in long construction periods and high costs but also slow progress and disrupt municipal traffic.

[0004] Therefore, developing a powerful intelligent device for the construction of large (ultra-large) diameter light-curing pipes can greatly improve work efficiency, reduce the labor intensity of workers, and save manpower. Summary of the Invention

[0005] This invention provides a fully automated laying and conveying device for large-diameter light-cured pipe repair materials, which solves the above-mentioned problems and enables such laying and conveying during municipal pipeline repair.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is: a fully automatic modular large-diameter light-curing pipe repair material laying and conveying device, comprising a laying and conveying device, wherein the laying and conveying device consists of a controller unit and multiple power conveying units, each power conveying unit consisting of a support, a roller group, a high-torque servo motor and a sensor integrated unit, wherein the sensor integrated unit is provided with a daisy-chain composite cable interface and a control interface, the multiple power conveying units are connected to each other by a daisy-chain composite cable, the control interface of the primary power conveying unit is electrically connected to the controller unit through a composite cable, the power conveying units are linearly distributed, and a connecting bracket is provided between the power conveying units, wherein the two ends of the connecting bracket are detachably connected to the support of the power conveying unit respectively.

[0007] Preferably, the roller assembly consists of two drive rollers and four free rollers. The two drive rollers are mounted parallel to each other on the support, and the four free rollers are respectively located at both ends of the two drive rollers and are inclined outwards. The drive rollers are connected to a high-torque servo motor for transmission.

[0008] Preferably, the high-torque servo motor is electrically connected to the controller unit through a sensor integration unit.

[0009] Preferably, the support of the power transmission unit is also provided with an auxiliary device for driving and controlling the roller assembly, and the auxiliary device is connected to the roller assembly for transmission.

[0010] Preferably, the sensor unit is equipped with a torque sensor for detecting the torque of the drive roller, a weight sensor for detecting the load on the roller assembly, and a force feedback sensor and an assist sensor that work in conjunction with the high-torque servo motor drive control.

[0011] Preferably, the controller unit integrates an industrial control host, a power servo unit, a wireless control module, and a wireless controller. The power servo unit and the wireless control module are electrically connected to the industrial control host, and the wireless control module is wirelessly connected to the wireless controller.

[0012] Preferably, the top surface of the controller unit is provided with a flip-top display screen, display instruments and operation keyboard, and the side of the controller unit is provided with a power input interface and a power input interface for the power transmission unit. The flip-top display screen, display instruments, operation keyboard and power input interface are respectively connected to the industrial control host for electrical signals, and the power input interface for the power transmission unit is electrically connected to the power servo unit.

[0013] Preferably, the connecting bracket consists of two parallel connecting rods and a set of intersecting reinforcing rods, with the reinforcing rods welded between the two connecting rods.

[0014] Preferably, the power delivery unit is available in various models depending on the diameter of the light-curing pipe.

[0015] Compared with the prior art, the advantages of the present invention are as follows:

[0016] (1) The laying and conveying equipment of the present invention adopts a modular design, and its power conveying unit can be added or removed arbitrarily according to the length of the pipeline, making the deployment very flexible. Each module is smaller and lighter than the overall equipment, and is very convenient to install and disassemble. The deployment is simple and quick, the laying time is short, and it can be put into use immediately after laying. It has obvious advantages over building large power conveying equipment.

[0017] (2) Each power transmission unit is self-powered, transforming rolling friction into mechanical transmission. Each power transmission unit is independently controlled. When the light-cured pipe is partially bent or arched, the transmission unit can be independently controlled to solve the bending or arching problem. It is more labor-saving for conveying heavy pipes, greatly reducing the labor intensity of workers, reducing the number of on-site workers, and saving construction costs.

[0018] (3) Each power transmission unit is equipped with a sensor, force feedback and assist device. Under the control of the controller unit, it can automatically control the power output of the power transmission unit, and can sense whether each power transmission unit is loaded with a sensor to avoid the impact of no load on the surface of the wear pipe, while reducing the risk of personnel and equipment being involved.

[0019] (5) The controller unit has an embedded operating system that can intelligently sense various parameters during the pipe conveying process and automatically achieve precise control of each power conveying unit according to the set program.

[0020] (6) The wireless controller unit enables technicians to operate the controller unit remotely when the pipe is very long, avoiding the embarrassment of the controller personnel having to sit next to the controller unit and listen to the instructions on the walkie-talkie, so as to achieve more accurate and timely control.

[0021] (7) In the event of an emergency, the entire system can be shut down immediately with the coordinated work of various sensors, force feedback and assistance, to ensure construction safety. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the power transmission unit of the present invention;

[0023] Figure 2 This is a schematic diagram of the external structure of the controller unit of the present invention;

[0024] Figure 3 This is a schematic block diagram of the controller unit of the present invention;

[0025] Figure 4This is a schematic diagram of the construction process of the present invention.

[0026] In the diagram: 1. Power transmission unit; 11. Drive roller; 12. Free roller; 13. High-torque servo motor; 14. Sensor integrated unit; 15. Power assist device; 16. Hand-in-hand composite cable interface; 17. Control interface; 18. Connecting bracket; 181. Connecting rod; 182. Reinforcing rod; 19. Support; 2. Controller unit; 21. Flip-top display screen; 22. Power transmission unit power interface; 23. Power input interface; 24. Display instrument; 25. Operation keyboard; 3. Photocurable tubing; 4. Transport vehicle. Detailed Implementation

[0027] The present invention will be further described below.

[0028] Example: A fully automated modular large-diameter UV-curable pipe repair material laying and conveying equipment, see [link / reference]. Figures 1 to 4 The system includes a laying and conveying device, which consists of a controller unit 2 and multiple power conveying units 1. Each power conveying unit 1 consists of a support 19, a roller group, a high-torque servo motor 13, and a sensor integration unit 14. The sensor integration unit 14 is equipped with a daisy-chain composite cable interface 16 and a control interface 17, which are connected by a wire. The daisy-chain composite cable interfaces 16 of the multiple power conveying units 1 are connected by a daisy-chain composite cable. The control interface 17 of the first-stage power conveying unit 1 is electrically connected to the power conveying unit power interface 22 of the controller unit 2 via a composite cable. The power conveying units 1 are linearly distributed, and a connecting bracket 1817 is provided between the power conveying units 1. The two ends of the connecting bracket 1817 are detachably connected to the support 19 of the power conveying unit 1. The present invention modularizes the conveying equipment used for laying light-curing pipes 3, forming multiple power conveying units 1. The multiple power conveying units 1 are electrically connected by a daisy-chain composite cable and are uniformly controlled by a controller unit 2. The power conveying unit 1 is small in size and light in weight, making it very convenient to transport. After being transported to the site, it can be used simply by connecting the connecting bracket 1817 and the cable.

[0029] The roller assembly consists of two drive rollers 11 and four free rollers 12. The two drive rollers 11 are mounted parallel to each other on the support 19, and the four free rollers 12 are respectively set at both ends of the two drive rollers 11 and are inclined outward. The rollers adopt a figure-eight upward curve similar to that of a belt conveyor to prevent the pipe from sliding to the left or right sides during the conveying process.

[0030] This invention solves the installation and transportation problems of on-site transmission equipment through modular design. However, since the material being transported is a light-cured pipe repair material, the light-cured pipe 3 is first transported directly to the site by a transport vehicle 4 during the well-down construction process. Then, a sliding diaphragm is laid between the truck bed and the pipe well, and the pipe is then directly dragged down into the well. A traction device is then connected for municipal pipeline repair. Because the light-cured pipe 3 is being dragged and unloaded from the truck, it inevitably experiences local bending and arching. Furthermore, the dragging speed of the traction device is not uniform during the repair process. The power transmission unit 1 needs to coordinate with the dragging process of the traction device to gradually lower the light-cured pipe 3 into the well. Therefore, the power transmission units 1 must coordinate with each other and work together as a whole to avoid uncontrolled continued transport of the pipe due to the traction device pausing or stopping, or unexpected events causing the pipe to stop transporting, resulting in local bending and arching, and detachment from the transport equipment. Therefore, this invention designs the drive control of the power transmission unit 1 as follows:

[0031] The drive roller 11 is connected to the high-torque servo motor 13 via a gear transmission. The output end of the high-torque servo motor 13 is equipped with a gearbox, which controls the speed change of the drive roller 11. To achieve more precise drive control of the drive roller 11, the high-torque servo motor 13 can provide a larger torque to the drive roller 11 for transporting large-diameter and heavy photocurable tubes 3. However, due to the large torque, its start-stop response is slow. Therefore, this invention adds an auxiliary power assist device 15. The auxiliary power assist device 15 is existing technology. Its function is to assist the drive roller 11 in rotation or stop when the speed of the drive roller 11 is insufficient or when an emergency stop or start is required.

[0032] The high-torque servo motor 13 is electrically connected to the controller unit 2 via a sensor integration unit 14. The sensor integration unit 14 is equipped with a torque sensor for detecting the torque of the drive roller 11, a weight sensor for detecting the load on the roller assembly, and a force feedback sensor and an assist sensor that cooperate with the drive control of the high-torque servo motor 13. The sensor integration unit 14 integrates all interfaces, electrical components, and sensor mounting mechanisms for easy installation and connection. The sensor integration unit 14 is fixed to the support 19.

[0033] The torque sensor detects the torque of the drive roller 11 and feeds the detection data back to the controller unit 2. The weight sensor detects whether the drive roller 11 is under load. When the weight sensor detects that the UV-curing tube is placed on the drive roller 11, the controller unit 2 starts the high-torque servo motor 13 and the power assist device 15 to prevent the drive roller 11 from spinning idly. When the UV-curing tube 3 is partially bent and arched, the weight sensor detects that the force transmission unit is not under load, so the controller unit 2 will control the high-torque servo motor 13 and the power assist device 15 to stop. The power transmission units 1 on both sides will straighten the arched part and allow the UV-curing tube 3 to fall back onto the drive roller 11 of the power transmission unit 1 before the controller unit 2 will continue to start the power transmission unit 1. Otherwise, the drive roller 11 will spin rapidly idling and tear the falling UV-curing tube 3. The force feedback sensor and the power assist sensor detect the drive of the high-torque servo motor 13 and the power assist device 15, so that the two cooperate to drive the drive roller 11.

[0034] The controller unit 2 integrates an industrial control host, a power servo unit, a wireless control module, and a wireless controller. The power servo unit and the wireless control module are electrically connected to the industrial control host. The industrial control host has an embedded operation control system for driving control of each module. The power servo unit is used for driving control of each power transmission unit 1. The wireless control module is wirelessly connected to the wireless controller for remote intercom communication.

[0035] The top surface of the controller unit 2 is provided with a flip-top display screen 21, a display instrument 24, and an operation keyboard 25. The display screen displays the control interface, the display instrument 24 displays the instrument status, and the operation keyboard 25 is used for command transmission and editing. The side of the controller unit 2 is provided with a power input interface 23 and a power transmission unit power interface 22. The flip-top display screen 21, the display instrument 24, the operation keyboard 25, and the power input interface 23 are respectively connected to the industrial control host for electrical signals. The power transmission unit power interface 22 is electrically connected to the power servo unit. The power input interface 23 is used to connect an external power source to power the controller unit 2, and the power transmission unit power interface 22 is used for cable connection between the controller unit 2 and the power transmission unit 1.

[0036] To achieve a stable connection between the power transmission units 1, this invention designs a connecting bracket 1817. The connecting bracket 1817 consists of two parallel connecting rods 181 and a set of intersecting reinforcing rods 182. The reinforcing rods 182 are welded between the two connecting rods 181. The connecting rods 181 connect the power transmission units 1 and can be fixed to the support 19 of the power transmission unit 1 with fastening bolts, facilitating installation and disassembly. The reinforcing rods 182 provide support and stability. Because the large-diameter UV-cured pipe repair material is relatively heavy, its weight, when placed on each power transmission unit 1, prevents relative slippage during transportation after connection via the connecting bracket 1817, resulting in good overall equipment stability. If uneven ground or other factors cause instability in the placement of the power transmission units 1, the connecting bracket 1817 can be fixed to the ground with expansion bolts, further increasing the stability of the transmission equipment. The power transmission unit 1 is available in various models according to the corresponding diameter of the light-curing pipe 3. The models are classified according to the light-curing pipe 3 of 600-800mm, 800-1000mm, and 1000-1500mm. The corresponding power transmission unit 1 can be transported to the site according to the pipe material requirements.

[0037] On-site implementation process:

[0038] 1. Based on the length and dimensions of the UV-curing tube 3, select the appropriate power unit model and arrange them at intervals of approximately 1-1.5m. Each power transmission unit 1 is fixed with a connecting bracket 1817 to prevent relative sliding on the ground due to insufficient ground friction. Each power transmission unit 1 is connected by a hand-operated composite cable, and the primary power transmission unit 1 is connected to the power transmission unit power interface 22 of the controller unit 2 via a composite cable.

[0039] 2. After the controller unit 2 is connected to the power supply, the circuit is checked. After confirming that the cable connection is normal, the unit is powered on for testing. The main test items are: the transmission response of the controller unit 2 to each power transmission unit 1, the control software sending power test signals to detect the mechanical operation of each power transmission unit 1, the communication establishment between the wireless controller and the controller unit, and the manual control response of the wireless controller.

[0040] 3. With the assistance of a crane, the UV-cured pipe 3 is placed on the pre-installed conveying equipment. During the process, the pipe placement function is selected in the controller unit 2. Under the pulling force of the traction winch, the UV-cured pipe 3 is slowly pulled out of the packaging box in the carriage. After each power transmission unit 1 comes into contact with the pipe, its internal sensors will feed back data such as real-time load, torque, force feedback, and power output parameters to the controller unit. The controller unit will then command each power transmission unit 1 to complete the placement of the pipe according to the pre-set pipe placement control mode.

[0041] 4. Pipe folding: Standardized pipe folding is completed using a combination of manual and mechanical methods, and temporary bundling is performed. After the pipe placement and folding are completed, the technician will inspect the pipes before lowering them into the well. Once the technical conditions are confirmed to be met, the pipe lowering construction order will be issued.

[0042] 5. Controller unit 2 initiates the pipe lowering function. Under the pull of the traction device, the pipe is slowly lowered into the well. At this time, each power transmission unit 1 transmits various parameters back to controller unit 2 in real time. Controller unit 2 directs each power transmission unit 1 to output auxiliary power in coordination and control the pipe conveying speed, driving the pipe to be gradually conveyed into the well under the pull of the traction device. At the same time, the force feedback and assist device 15 of power transmission unit 1, when it senses that the traction device has paused or stopped pulling, or when the pipe conveying stops due to an unexpected event, will immediately stop the auxiliary conveying power under the control of controller unit 2 to prevent the pipe from continuing to be conveyed uncontrollably.

[0043] 6. After the end of the pipe passes through the power transmission unit 1 in sequence, the sensor of the power transmission unit 1 detects that there is no load. After the sensor feeds back the signal to the controller unit 2, the controller unit 2 cuts off the power output of the power transmission unit 1 to avoid no-load and further reduce the safety risk of personnel and equipment being involved.

[0044] 7. During the process, the technician holds a wireless controller to check the condition of the pipes on each power transmission unit 1, reports the situation to the staff at the controller unit 2 through the wireless controller, and sends start and stop commands, and can adjust the pipe conveying speed in real time.

[0045] 8. After construction is completed, disconnect the power, remove the composite control cable, remove the connecting bracket 1817, and recover the power transmission unit 1.

[0046] The above provides a detailed description of the fully automatic modular large-diameter light-curing pipe repair material laying and conveying equipment provided by the present invention. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Modifications and improvements to the present invention are possible without exceeding the concept and scope specified in the appended claims. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A fully automatic modular large-diameter light-curing pipe repair material laying and conveying device, comprising laying and conveying equipment, characterized in that: The laying and conveying equipment consists of a controller unit and multiple power conveying units. Each power conveying unit comprises a support, a roller assembly, a high-torque servo motor, and a sensor integration unit. The sensor integration unit is equipped with a daisy-chain cable interface and a control interface. The multiple power conveying units are connected via daisy-chain cables. The control interface of the primary power conveying unit is electrically connected to the controller unit via a composite cable. The power conveying units are linearly distributed and connected by connecting brackets. Both ends of the connecting brackets are detachably connected to the supports of the power conveying units. The supports of the power conveying units are also equipped with auxiliary devices for driving and controlling the roller assembly. These auxiliary devices are connected to the roller assembly transmission. Next, the sensor integration unit is equipped with a torque sensor for detecting the torque of the drive roller, a weight sensor for detecting the load on the roller assembly, and a force feedback sensor and an assist sensor that work in conjunction with the high-torque servo motor drive control. When the weight sensor detects that the UV-curing tube is placed on the drive roller, the controller unit starts the high-torque servo motor and the assist device. When the UV-curing tube is partially bent and arched, the weight sensor detects that the power delivery unit is not under load, so the controller unit controls the high-torque servo motor and the assist device to stop. The controller unit will only start the power delivery unit again when the power delivery units on both sides straighten the arched part and the UV-curing tube falls back onto the drive roller of the power delivery unit.

2. The fully automatic modular large-diameter photocurable pipe repair material laying and conveying equipment according to claim 1, characterized in that: The roller assembly consists of two drive rollers and four free rollers. The two drive rollers are mounted parallel to each other on the support, and the four free rollers are respectively set at both ends of the two drive rollers and are inclined outwards. The drive rollers are connected to a high-torque servo motor for transmission.

3. The fully automatic modular large-diameter photocurable pipe repair material laying and conveying equipment according to claim 1, characterized in that: The high-torque servo motor is electrically connected to the controller unit through a sensor integration unit.

4. The fully automatic modular large-diameter photocurable pipe repair material laying and conveying equipment according to claim 1, characterized in that: The controller unit integrates an industrial control host, a power servo unit, a wireless control module, and a wireless controller. The power servo unit and the wireless control module are electrically connected to the industrial control host, and the wireless control module is wirelessly connected to the wireless controller.

5. The fully automatic modular large-diameter photocurable pipe repair material laying and conveying equipment according to claim 4, characterized in that: The top surface of the controller unit is equipped with a flip-top display screen, display instruments, and an operation keyboard. The side of the controller unit is equipped with a power input interface and a power input interface for the power transmission unit. The flip-top display screen, display instruments, operation keyboard, and power input interface are respectively connected to the industrial control host for electrical signals. The power input interface for the power transmission unit is electrically connected to the power servo unit.

6. The fully automatic modular large-diameter photocurable pipe repair material laying and conveying equipment according to claim 1, characterized in that: The connecting bracket consists of two parallel connecting rods and a set of intersecting reinforcing rods, with the reinforcing rods welded between the two connecting rods.

7. The fully automatic modular large-diameter photocurable pipe repair material laying and conveying equipment according to claim 1, characterized in that: The power delivery unit is available in various models based on the corresponding diameter of the light-curing tubing.

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