Multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting

Abstract

The multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting comprises a PE material sleeve body, two sets of gas concentration sensors are symmetrically installed on the outer arc face of the PE material sleeve body, and a resistance wire is installed in the PE material sleeve body in an embedded mode; a plurality of groups of polymer filling materials are embedded in the PE material sleevelet body. By adding a layer of uniform PE material below the resistance wire and using a high polymer material fused with PE on the outer side, a welding interface is enabled to be smoother and more sealed, so that the welding consistency and quality are improved, and the air leakage risk caused by welding defects is reduced; each sleevelet has the functions of real-time data monitoring and unique identity recognition, so that maintenance and detection work is more convenient and accurate, data from the sleevelets are collected and analyzed in real time through the data management platform, decision support is provided, maintenance cost is reduced, and reliability of the system is improved.

Description

Technical Field

[0001] The invention relates to the technical field of polyethylene gas pipelines, and in particular to a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting. Background Art

[0002] Polyethylene (PE) materials are widely used in urban gas pipe network systems due to their excellent chemical stability and mechanical properties. In particular, in the gas pipeline connection technology, electric fusion connection is widely used as an efficient connection method due to its simple construction and high connection reliability. The electric fusion connection technology mainly heats the contact part of the pipe and the sleeve by the built-in resistance wire of the electric fusion sleeve, so that the contact part of the pipe and the sleeve is melted, and a firm bond is formed after cooling.

[0003] However, the existing electric fusion connection technology still has some shortcomings, especially in terms of the accuracy of the resistance wire position and the uniformity of heat distribution during the welding process. Improper resistance wire position and uneven heat distribution can easily lead to unstable welding quality, cold welding or over-welding, which may evolve into a hidden danger of gas leakage in the pipeline during long-term service.

[0004] There are many electric fusion sleeve products on the market. These products usually have basic electric fusion functions, that is, they connect PE pipes by heating the embedded resistance wire. However, these traditional electric fusion sleeves generally have several problems:

[0005] 1. Uneven heat distribution: Due to the limitations of the resistance wire and the material itself, the heat distribution inside the sleeve may be uneven, resulting in inconsistent strength at the welded joint, which is prone to microscopic holes or cold welding problems.

[0006] 2. Lack of intelligent monitoring: Most existing products lack a system that can monitor the temperature and pressure of the electric fusion welding part in real time and accurately locate the position of the pipe. Maintenance personnel cannot obtain the status of the buried electric fusion joint in real time, which increases the construction risk.

[0007] 3. Difficulty in maintenance: After long-term underground service, the location information and status of existing electric fusion sleeve products are difficult to obtain in real time, resulting in certain difficulties in detection, maintenance and management.

[0008] Although the prior art provides the basic design of the electric fusion sleeve, there is no electric fusion sleeve product that can fully solve the above problems. The technical solution closest to the present invention may include an electric fusion sleeve with a temperature sensor, however, these solutions usually still fail to effectively solve the problems of resistance wire position adjustment and heat uniform distribution, and the integration of the monitoring system often does not support real-time data processing and feedback adjustment, and its functions and effects are limited, so now there is a need for a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting. Summary of the invention

[0009] The purpose of the present invention is to provide a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting, which has significant advantages in improving welding quality, simplifying maintenance operations and enhancing system management efficiency, so as to solve the technical problems mentioned in the background technology.

[0010] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting, comprising a PE material sleeve body, two groups of gas concentration sensors are symmetrically installed on the outer arc surface of the PE material sleeve body, a resistance wire is embedded and installed inside the PE material sleeve body, and several groups of polymer filling materials are embedded and installed inside the PE material sleeve body;

[0011] The winding spacing in the middle of the resistance wire is wider, and the winding spacing at both ends of the resistance wire is narrower;

[0012] The polymer filling material is embedded in the PE material sleeve body and then fixed by thermal compatible welding.

[0013] Preferably, a positioning chip is installed on the outer arc surface of the PE material sleeve body in the middle of the two groups of gas concentration sensors, an observation hole is opened on the outer arc surface of the PE material sleeve body corresponding to the narrower winding spacing at both ends of the resistance wire, and a welding hole is installed on the outer arc surface of the PE material sleeve body on one side of the observation hole.

[0014] In addition, the present invention also provides a method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting, comprising the following steps:

[0015] (1) Improved welding interface quality: By adding a layer of polyethylene (PE) material under the resistance wire by injection molding, the welding interface is ensured to be smoother, thereby improving welding quality;

[0016] (2) Interface smoothness optimization: By injecting multiple layers of polyethylene material under the resistance wire, the welding interface is made smoother, significantly reducing stress concentration and welding defects caused by surface irregularities.

[0017] (3) Polymer material design: A special polymer material that can be thermally fused with PE is designed at the end of the PE sleeve body's electrofusion connection area. The material is a modified material with PE blocks (the blocks contain segments containing chlorine or specific polar functional groups);

[0018] (4) End reinforcement principle: A reinforcing material with a lower melting point is selected in the design so that it melts and fuses synchronously with the PE sleeve body.

[0019] Preferably, the PE material helps to transfer heat evenly and reduce welding defects caused by misalignment of the resistance wire;

[0020] A flat welding interface helps to improve the uniformity of heat transfer during the welding process, thereby ensuring that the entire welding area is heated evenly and the degree of melting of the weld is consistent, ultimately improving the welding quality and durability.

[0021] Preferably, the PE sleeve body has a multi-layer structure, higher bonding strength and good thermal stability on the basis of being thermally compatible with PE;

[0022] During the welding process, this material can flow well due to its low hot melt viscosity and good thermal stability, filling and sealing the gaps in the interface, ensuring the welding integrity of the joint and strengthening both ends;

[0023] The mechanical properties are greater than those of high-density polyethylene, thereby resisting external stress and enhancing the sealing effect of the welding parts and the overall mechanical strength.

[0024] Preferably, when the welding temperature exceeds 120°C, the olefin chain segments begin to undergo thermal motion and diffuse with the interface of the PE material sleeve body. The polar groups further enhance the bonding force with the inner wall of the PE material sleeve body, greatly improving the mechanical strength of the welding end of the PE material sleeve body.

[0025] Preferably, a uniform layer of PE material is added under the resistance wire and a polymer material that melts with PE is used on the outside to ensure that the welding interface is smoother and more sealed, thereby improving the consistency and quality of welding and reducing the risk of air leakage due to welding defects.

[0026] Preferably, the gas concentration sensor and positioning chip enable each PE material sleeve body to have real-time data monitoring and unique identity recognition functions, making maintenance and detection work more convenient and accurate.

[0027] Preferably, the data from the PE material sleeve body is collected and analyzed in real time through the data management platform to provide decision support, optimize maintenance strategies and prevent potential failures in advance, reduce maintenance costs and improve system reliability.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] The present invention significantly improves the welding quality and long-term service reliability of the electric fusion connection sleeve through structural optimization, multi-layer material design and intelligent sensor combination, ensures that high mechanical strength and sealing performance can be maintained in various complex environments, greatly improves the welding quality and subsequent operation and maintenance efficiency of the electric fusion connection sleeve of the PE gas pipeline, thereby significantly reducing operating costs and improving the overall reliability and safety of the gas pipe network system, thereby ensuring the safe and stable operation of the urban gas pipe network;

[0030] By adding a uniform layer of PE material under the resistance wire and using a polymer material that melts with PE on the outside, the welding interface is ensured to be smoother and more sealed, thereby improving the consistency and quality of welding and reducing the risk of air leakage caused by welding defects. Through the integrated sensors, each cuff has real-time data monitoring and unique identity recognition functions, making maintenance and inspection work more convenient and accurate. The data from the cuff is collected and analyzed in real time through the data management platform, providing decision support, optimizing maintenance strategies and preventing potential failures in advance, reducing maintenance costs and improving system reliability.

[0031] The integration of these designs and technologies gives the present invention significant advantages in improving welding quality, simplifying maintenance operations and enhancing system management efficiency, and is expected to be widely used in the field of urban gas pipeline networks. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0033] Figure 2 It is a schematic cross-sectional view of the overall structure of the present invention.

[0034] In the figure: 1. PE material sleeve body; 2. Gas concentration sensor; 3. Resistance wire; 4. Positioning chip; 5. Welding hole; 6. Observation hole; 7. Polymer filling material. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings in the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0036] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] like Figure 1-Figure 2 As shown, the present invention provides a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting, including a PE material sleeve body 1, two groups of gas concentration sensors 2 are symmetrically installed on the outer arc surface of the PE material sleeve body 1, a resistance wire 3 is embedded and installed inside the PE material sleeve body 1, and several groups of polymer filling materials 7 are embedded and installed inside the PE material sleeve body 1.

[0038] The PE material sleeve body 1 is set to ensure uniform temperature distribution in the welding area, avoid local overheating or cold welding, and improve welding quality. The overall combination of the PE material sleeve body 1 is to inject a layer of PE material under the resistance wire 3 as a buffer layer between the resistance wire 3 and the pipe. This layer of PE material can melt first when the resistance wire 3 is heated, and form a more uniform contact interface with the outer surface of the pipe. Through this layer of PE material, heat can be more evenly transferred to the entire welding interface, preventing local overheating, ensuring that the electric fusion welding interface is smoother, improving the overall strength and sealing performance of the welding, and reducing defects generated during the welding process, such as holes and cracks.

[0039] The winding spacing of the resistance wire 3 in the middle is wider, and the winding spacing of the two ends of the resistance wire 3 is narrower. The resistance wire 3 is installed inside the PE material sleeve body 1 in a winding manner in which the two sides are tightly wound and the middle is scattered.

[0040] The polymer filling material 7 is embedded in the PE material sleeve body 1 and fixed by thermal compatible welding. The inner polymer filling material 7 improves the structural integrity of the welded joint and fills the tiny gaps that may be generated during the welding process. A layer of polymer filling material 7 compatible with PE material is designed in the innermost layer of the PE material sleeve body 1. The material melts during the electric fusion welding process and forms a firm bond with the pipe. The polymer filling material 7 has excellent fluidity and can flow into any gap during the welding process to ensure the tightness of the joint. By melting and filling the gaps during the electric fusion welding process, the strength and air tightness of the joint are enhanced, the durability of the welded joint is improved, and leakage caused by stress and environmental changes in a long-term service environment is prevented.

[0041] A positioning chip 4 is installed on the outer arc surface of the PE material sleeve body 1, which is located in the middle of the two groups of gas concentration sensors 2. An observation hole 6 is opened on the outer arc surface of the PE material sleeve body 1 at a position where the winding spacing at both ends of the resistance wire 3 is narrow. A welding hole 5 is installed on the outer arc surface of the PE material sleeve body 1, which is located on one side of the observation hole 6. The set gas concentration sensor 2 and positioning chip 4 are used as intelligent processing modules to provide real-time monitoring of the status of the welding joint and realize subsequent positioning, differentiation and detection. A temperature sensor is also embedded in the PE material sleeve body 1. The temperature sensor is embedded in the PE material sleeve body 1 to monitor the temperature changes during the welding process and in the later service in real time. At the same time, a stress sensor can also be installed on the outer end of the PE material sleeve body 1 to monitor the stress borne by the welding joint during service and determine whether the connection is affected by abnormalities.

[0042] Temperature and stress sensors monitor the status of the joints in real time, detect potential hazards in time and avoid accidents.

[0043] At the same time, in order to realize remote monitoring and data analysis of the welding process and subsequent status, the sensor data is analyzed, including temperature and stress changes, to evaluate the welding quality and service status. The temperature, stress and other data of each welding joint are uploaded to the monitoring platform to realize remote monitoring. Through the data processing unit, the data is analyzed, the welding quality is evaluated, and the remaining life of the joint is predicted. According to the sensor data, it is judged in real time whether there is any abnormal situation, such as excessive temperature or abnormal stress, and an alarm signal is issued in time.

[0044] The present invention also provides a method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting, comprising the following steps:

[0045] (1) Improvement of welding interface quality: By adding a layer of polyethylene PE material under the resistance wire 3 by injection molding, the welding interface is ensured to be smoother, thereby improving the welding quality; the PE material helps to evenly transfer heat and reduce welding defects caused by the misalignment of the resistance wire 3; the smooth welding interface helps to improve the uniformity of heat transfer during welding, thereby ensuring that the entire welding area is heated evenly and the melting degree of the weld is consistent, ultimately improving the welding quality and durability; the PE material sleeve body 1 has a multi-layer structure, higher bonding strength and good thermal stability on the basis of being thermally fused with PE;

[0046] (2) Interface smoothness optimization: By injecting multiple layers of polyethylene material under the resistance wire 3, the welding interface is made smoother, significantly reducing stress concentration and welding defects caused by surface irregularities; during the welding process, this material can flow well due to its low hot melt viscosity and good thermal stability, filling and sealing the gaps in the interface, ensuring the welding integrity of the joint and strengthening both ends; the mechanical properties are greater than those of high-density polyethylene, thereby achieving resistance to external stress and enhancing the sealing effect and overall mechanical strength of the welding part.

[0047] (3) Polymer material design: A special polymer material that can be thermally fused with PE is designed at the end of the electric fusion connection area of ​​the PE material sleeve body 1. The material is a modified material with a PE block, and the block contains a chlorine-containing or specific polar functional group chain segment. When the welding temperature exceeds 120°C, the olefin chain segment begins to undergo thermal motion and diffuses with the interface of the PE material sleeve body 1. The polar group further enhances the bonding force with the inner wall of the PE material sleeve body 1, greatly improving the mechanical strength of the welding end of the PE material sleeve body 1.

[0048] (4) End reinforcement principle: A reinforcing material with a lower melting point is selected in the design so that it melts and fuses synchronously with the PE material sleeve body 1. A uniform layer of PE material is added under the resistance wire 3 and a polymer material that melts with PE is used on the outside to ensure that the welding interface is smoother and more sealed, thereby improving the consistency and quality of welding and reducing the risk of air leakage caused by welding defects.

[0049] The gas concentration sensor 2 and the positioning chip 4 enable each PE material sleeve body 1 to have real-time data monitoring and unique identity recognition functions, making maintenance and inspection work more convenient and accurate. The data management platform collects and analyzes data from the PE material sleeve body 1 in real time, provides decision support, optimizes maintenance strategies and prevents potential failures in advance, reduces maintenance costs and improves system reliability, and provides operators with the ability to monitor and manage the welding process in real time. A visual interface is provided on the monitoring terminal to display real-time temperature, stress, position and other information, supports long-term data storage, analysis and report generation, and facilitates managers to view welding history and maintenance records.

[0050] Used for real-time monitoring, operators can view the status of each welding joint in real time through the interface, including parameters such as temperature and stress, and generate reports based on sensor data to help evaluate the quality and long-term performance of the welding joints. When an abnormality is found, the system can issue instructions to maintain or isolate the corresponding welding joints to ensure the safety of the pipeline network.

[0051] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting, characterized in that: It comprises a PE material sleeve body (1), two groups of gas concentration sensors (2) are symmetrically mounted on the outer arc surface of the PE material sleeve body (1), a resistance wire (3) is embedded and mounted inside the PE material sleeve body (1), and a plurality of groups of polymer filling materials (7) are embedded and mounted inside the PE material sleeve body (1); The winding spacing in the middle of the resistance wire (3) is relatively wide, and the winding spacing at both ends of the resistance wire (3) is relatively narrow; The polymer filling material (7) is embedded in the PE material sleeve body (1) and then fixed by thermal compatible welding.

2. The multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 1 is characterized in that: A positioning chip (4) is installed on the outer arc surface of the PE material sleeve body (1) located in the middle of the two groups of gas concentration sensors (2), an observation hole (6) is opened on the outer arc surface of the PE material sleeve body (1) at a position where the winding spacing at both ends of the resistance wire (3) is narrow, and a welding hole (5) is installed on the outer arc surface of the PE material sleeve body (1) located on one side of the observation hole (6).

3. A method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claims 1-2, characterized in that: The steps include: (1) Improvement of welding interface quality: by adding a layer of polyethylene (PE) material by injection molding under the resistance wire (3), the welding interface is ensured to be smoother, thereby improving the welding quality; (2) Interface smoothness optimization: By injecting multiple layers of polyethylene material under the resistance wire (3), the welding interface is made smoother, significantly reducing stress concentration and welding defects caused by surface irregularities. (3) Polymer material design: A special polymer material that can be thermally fused with PE is designed at the end of the electric fusion connection area of ​​the PE material sleeve body (1). The material is a modified material with a PE block (the block contains a segment containing chlorine or a specific polar functional group); (4) End reinforcement principle: A reinforcement material with a lower melting point is selected in the design so that it melts and fuses synchronously with the PE material sleeve body (1).

4. The method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 3 is characterized in that: The PE material helps to transfer heat evenly and reduce welding defects caused by misalignment of the resistance wire (3); A flat welding interface helps to improve the uniformity of heat transfer during the welding process, thereby ensuring that the entire welding area is heated evenly and the degree of melting of the weld is consistent, ultimately improving the welding quality and durability.

5. The method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 3 is characterized in that: The PE material sleeve body (1) has a multi-layer structure, higher bonding strength and good thermal stability based on its thermal fusion with PE; During the welding process, this material can flow well due to its low hot melt viscosity and good thermal stability, filling and sealing the gaps in the interface, ensuring the welding integrity of the joint and strengthening both ends; The mechanical properties are greater than those of high-density polyethylene, thereby resisting external stress and enhancing the sealing effect of the welding parts and the overall mechanical strength.

6. The method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 3 is characterized in that: When the welding temperature exceeds 120° C., the olefin chain segments begin to undergo thermal motion and diffuse with the interface of the PE material sleeve body (1). The polar groups further enhance the bonding force with the inner wall of the PE material sleeve body (1), thereby greatly improving the mechanical strength of the welding end of the PE material sleeve body (1).

7. The method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 3 is characterized by: A uniform layer of PE material is added under the resistance wire (3) and a polymer material that melts with PE is used on the outside to ensure that the welding interface is smoother and more sealed, thereby improving the consistency and quality of welding and reducing the risk of air leakage caused by welding defects.

8. The method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 3 is characterized by: Through the gas concentration sensor (2) and the positioning chip (4), each PE material sleeve body (1) has real-time data monitoring and unique identity recognition functions, making maintenance and detection work more convenient and accurate.

9. The method for processing and using a multifunctional intelligent polyethylene gas pipeline electric fusion welding pipe fitting according to claim 3 is characterized by: The data management platform collects and analyzes data from the PE sleeve body (1) in real time, provides decision support, optimizes maintenance strategies and prevents potential failures in advance, reduces maintenance costs and improves system reliability.

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