Autonomous Laser Testing of Tubular Members
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Solution Overview
Problem
Tubular members with non-conforming cross-sections or varying wall thicknesses can cause issues in hydrocarbon and chemical piping networks, leading to potential failures and inefficiencies.
Innovation Solution
An autonomous machine equipped with a mobile base, extendable appendages, and laser sensors is used to perform laser drift testing, assessing the quality of tubular members by emitting and receiving laser signals along their inner and outer surfaces to determine surface quality and wall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual testing methods are used, then operational simplicity is maintained, but testing accuracy and quality assessment precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical measurement system. The system uses a camera to capture images of the tubular member, and a processor automatically analyzes these images to determine cross-sectional shape and wall thickness, eliminating the need for manual mechanical measurement tools and operations.
Solution Approach 2:
The patent creates a visual copy (image) of the tubular member's cross-section using a camera, and then analyzes this copy to determine geometric properties. This allows accurate measurement without physically contacting or disturbing the actual tubular member, maintaining its integrity while obtaining precise measurements.
2Reliability
If comprehensive quality testing is performed, then product quality assurance improves, but testing time and productivity deteriorate
Solution Approach 1:
The patent enables continuous quality testing by capturing images of tubular members as they pass through the inspection station and automatically processing these images in real-time. The system continuously acquires, processes, and analyzes data without interruption, maintaining constant monitoring of product quality while keeping the production line moving.
Solution Approach 2:
The patent performs preliminary quality assessment by capturing images and analyzing cross-sectional geometry before the tubular member proceeds to subsequent manufacturing or assembly steps. This early detection of defects prevents non-conforming products from moving further in the production process, saving time and resources.
3Productivity
If automated testing systems are implemented, then testing speed and productivity improve, but device complexity and initial investment deteriorate
Solution Approach 1:
The patent employs a multi-functional system where a single integrated apparatus performs multiple functions: image capture, cross-sectional shape analysis, wall thickness measurement, and defect detection. This universal testing station eliminates the need for multiple separate specialized devices, reducing overall system complexity while maintaining high productivity.
Solution Approach 2:
The system is designed to be self-sufficient, with the processor automatically analyzing captured images and determining quality parameters without requiring constant human intervention. The automated image processing and analysis capabilities allow the system to perform comprehensive testing independently, maintaining high speed while managing complexity through automation.
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 autonomous machine provides efficient, autonomous, and accurate qualitative and quantitative testing of tubular members, ensuring they meet quality standards and are free of defects, thereby enhancing the reliability of hydrocarbon and chemical piping systems.
Implementation Method 1
at least one laser emitter configured to move on the at least one laser sensor plate and emit a laser signal along a tubular member; and at least one laser receiver coupled to the at least one laser sensor plate and configured to receive a reflected laser signal along the tubular member
Implementation Method 2
receive a reflected laser signal along the tubular member
Data Source
AI summary
An autonomous machine includes a body; a mobile base coupled to the body and configured to move the body between a plurality of locations; and at least one extendable appendage coupled to, and configured to extend from, the body. The at least one extendable appendage includes at least one laser sensor plate. The at least one laser sensor plate includes at least one laser emitter configured to move on the at least one laser sensor plate and emit a laser signal along a tubular member; and at least one laser receiver coupled to the at least one laser sensor plate and configured to receive a reflected laser signal along the tubular member. The emitted laser signal and the reflected laser signal is indicative of a quality of the tubular member.