Digital Thread Inspection System for Pipe Connections
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Solution Overview
Problem
Conventional visual thread inspection methods for pipe sections and threaded connections are subjective, prone to human error, and inconsistent due to environmental factors, which can lead to safety and operational issues.
Innovation Solution
A digital inspection system using integrated laser measurement, optical sensors, and phased-array/UT technology for comprehensive inspection of pipe sections and threaded connections, providing objective and accurate data through a compact, portable assembly with automated rotation and CNC-controlled systems for precise measurement and reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional visual thread inspection methods are used, then the inspection process is simple and inexpensive, but the results are subjective, inconsistent, and prone to human error
Solution Approach 1:
The patent replaces the mechanical visual inspection system with an optical measurement system. Digital cameras, laser scanners, and optical sensors capture images and measurements of threaded connections, eliminating human subjectivity. The system uses automated image processing and analysis algorithms to objectively evaluate thread geometry, replacing the inspector's visual assessment with precise digital measurement.
Solution Approach 2:
The patent creates digital copies of the physical threaded connections through high-resolution imaging and laser scanning. These digital replicas allow for repeated analysis, storage, and comparison without requiring physical re-inspection. The digital models preserve all geometric details and can be analyzed multiple times with consistent results, eliminating the inconsistency of human inspection.
2Reliability
If digital inspection systems with multiple sensors are used, then measurement precision and objectivity are improved, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple inspection functions into a single integrated device. Digital cameras, laser scanners, and optical sensors are combined in one apparatus that can simultaneously capture multiple types of data. This integration reduces the complexity of using separate devices and simplifies the inspection process while maintaining high reliability through multi-functional verification.
Solution Approach 2:
The inspection system is designed with multi-functionality to handle various inspection requirements. The same device can perform geometric measurements, surface defect detection, and thread profile analysis. This universal approach improves reliability by providing consistent results across different inspection tasks while avoiding the complexity of maintaining multiple specialized devices.
3Measurement precision
If automated digital inspection systems are deployed, then human error is eliminated and accuracy is improved, but the complexity of operation and deployment increases
Solution Approach 1:
The inspection system performs self-calibration and automated analysis without requiring operator intervention. The device automatically captures images, processes measurements, compares results against specifications, and generates inspection reports. This self-service capability eliminates human error in measurement and analysis while keeping the operation simple—operators only need to position the device and initiate the inspection sequence.
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 system reduces human error and subjectivity, ensuring consistent and accurate inspection results, allowing for real-time data acquisition and remote monitoring, and generating reports that verify compliance with OEM standards, thereby enhancing safety and operational integrity.
Implementation Method 1
utilizing some combination of integrated laser measurement, optical sensors, phased-array and/or UT technology
Implementation Method 2
optical sensors, phased-array and/or UT technology
Implementation Method 3
phased-array and/or UT technology
Data Source
AI summary
A compact inspection assembly comprising digital sensors and/or laser measurement systems to validate attributes of pipe and associated threaded connections. An elongate body member is partially inserted into a central bore of a pipe section. A stabilizing centralizer assembly is selectively expanded to engage against the inner surface of the pipe section and prevent axial and rotational movement of the body section relative to the pipe section. An automated sensor assembly, attached to the body member and positioned in proximity to a threaded connection, measures data regarding the pipe and associated threaded connections. The measured and recorded data can be compared to predetermined standards (such as, for example, original equipment manufacturer and/or end user specifications or requirements) to verify pipe/connection compliance with desired standards.