Adaptive In-Pipe Welding Repair for Large Length-to-Diameter Pipelines
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Solution Overview
Problem
Current pipeline rehabilitation technologies are ineffective in repairing localized spots, require extensive excavation, and lack efficiency in cleaning and repairing large length-to-thin ratio pipelines, especially in areas with limited accessibility.
Innovation Solution
A flexible adaptive pipeline repair device with integrated sandblasting, preheating, and welding mechanisms, featuring adjustable radius and universal joints, enabling 360° repair and self-cleaning capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external rehabilitation methods are used, then repair coverage is comprehensive, but excavation requirements and construction costs increase significantly
Solution Approach 1:
The patent employs a flexible robotic device with a thin, adaptable structure that can be inserted into pipelines without excavation. The device features a flexible body with integrated sandblasting, cleaning, and welding components that conform to the pipeline interior, enabling comprehensive repair coverage while avoiding external excavation work.
2Ease of manufacture
If internal rehabilitation methods are used, then excavation is avoided, but repair effectiveness for localized spots and cleaning efficiency are insufficient
Solution Approach 1:
The patent integrates multiple repair functions including sandblasting, cleaning, preheating, and welding into a single robotic device. This merging of functions enables the device to effectively clean and repair localized spots within the pipeline while maintaining excavation-free operation, thereby improving repair effectiveness without requiring excavation.
3Ease of operation
If traditional welding repair methods are used, then repair convenience is achieved, but labor intensity and operational complexity increase
Solution Approach 1:
The robotic device performs sandblasting, cleaning, preheating, and welding operations autonomously once positioned in the pipeline. The integrated system self-manages the repair process without requiring external operator intervention for each step, reducing labor intensity while maintaining operational convenience through automated sequencing of repair tasks.
4Device complexity
If handheld torch repair methods are used, then equipment simplicity is maintained, but repair quality and efficiency decrease
Solution Approach 1:
The patent replaces manual handheld torch operations with an automated robotic system that integrates sandblasting, cleaning, preheating, and welding functions. This substitution of mechanical systems enables precise control over repair parameters, consistent repair quality, and continuous operation, thereby significantly improving repair efficiency while managing device complexity through modular integration.
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 device achieves efficient, high-quality repairs in large length-to-thin ratio pipelines with reduced labor intensity, capable of sandblasting, cleaning, preheating, and welding in all positions, including bends.
Implementation Method 1
a compressed gas tank to power the sandblasting work of the sandblasting head
Implementation Method 2
the heating mechanism includes a heating rack and a fourth motor for driving the rotation of the heating rack
Implementation Method 3
the welding repair mechanism includes a welding gun, a fifth motor for adjusting the angle of the welding gun
Data Source
AI summary
A flexible adaptive large length to thin ratio pipeline intelligent repair device is provided. The walking mechanism includes a walking bracket and a radius adjustment assembly. The radius adjustment assembly is located in the middle of the walking bracket. The first motor for driving the radius adjustment assembly is set in the middle of the walking mechanism, and the second motor for driving the movement of the walking bracket is set on the walking bracket. The ends of several groups of connecting rods are removably connected to the working part, which includes the pre-welding sandblasting mechanism, the heating mechanism and the welding repair mechanism. A positioning sensor is set on the walking bracket. The variable-diameter all-position intelligent pipe internal repair device can integrate pre-welding cleaning, preheating, welding repair and post-welding heat treatment.