Thermal Spraying Head for Duct Surface Regeneration
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Solution Overview
Problem
Vapor conduits in industrial installations, such as energy production and chemical industry facilities, face severe abrasion and potential chemical aggression, leading to material weakening and safety risks due to wear and the risk of leaks or toxic substances, necessitating frequent and costly maintenance and potential radioactive leaks.
Innovation Solution
A mobile device with a moving support, radial and transverse adjustment mechanisms, and a thermal spraying head for regenerating conduit surfaces, equipped with sensors for detecting changes in direction, chemical compounds, and radioactivity, allowing for efficient and safe internal surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a detection and thermal spraying device is deployed through a conduit end to inspect and restore inner surfaces, then the conduit can be maintained without replacement and safety risks reduced, but the device complexity and operational difficulty increase due to the need for positioning, centring, and repositioning mechanisms
Solution Approach 1:
The device integrates multiple functions into a single unit: detection sensors for inspecting conduit condition, thermal spraying apparatus for restoring inner surfaces, positioning mechanisms for navigation, and centring components for alignment. This multi-functionality allows one device to perform inspection, diagnosis, and restoration operations, reducing the need for multiple separate equipment systems while maintaining conduit safety
Solution Approach 2:
The detection and thermal spraying devices are deployed through the conduit end in a nested manner, where the spraying head and sensors are contained within the positioning and centring mechanisms. This nested structure allows the entire system to be inserted through a single conduit opening while maintaining all necessary functional components, managing complexity through hierarchical integration
2Manufacturing precision
If the device is taken to the end furthest from insertion and returned closer for continuous treatment, then complete conduit coverage is achieved, but the loss of time and productivity increase due to multiple repositioning operations
Solution Approach 1:
The device incorporates dynamic repositioning capabilities with motors and pulling means that enable continuous movement along the conduit length. The system can dynamically adjust its position from the insertion end to the far end and return, allowing complete conduit coverage while minimizing idle time through automated or semi-automated traversal control
Solution Approach 2:
The device performs preliminary detection and assessment operations as it travels to the far end of the conduit, identifying areas requiring restoration before the return journey. This preliminary action allows planning of restoration operations in advance, reducing total time by avoiding repeated inspection cycles and enabling continuous treatment during the return traversal
3Adaptability or versatility
If mechanical, optical, acoustic or electric means are used to recognise changes in direction, then the device can navigate complex conduit paths, but the device complexity and cost increase
Solution Approach 1:
The navigation system merges multiple sensing modalities (mechanical sensors for physical contact detection, optical sensors for visual alignment, acoustic sensors for structural analysis, and electric sensors for field detection) into a single integrated direction-change recognition system. This combined approach enables comprehensive navigation capability through complex conduit paths while sharing common processing and control infrastructure, managing the complexity through unified system architecture
4Stability of the object's composition
If tripods are used for positioning and securing the device in the pipeline, then stability is improved, but the device complexity increases and coating deficiencies in tripod zones require reduced distances
Solution Approach 1:
The positioning system is segmented into multiple independent tripod units distributed along the device length, with each tripod providing localized stabilization. This segmentation allows the device to maintain stability in different conduit sections independently, reducing the impact of coating deficiencies to localized zones rather than requiring system-wide distance reductions, while managing complexity through modular tripod designs
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 solution enables smooth centring and regeneration of conduit surfaces, reducing wear and maintenance costs, ensuring safety by preventing leaks and detecting hazardous substances, thus maintaining operational conditions and minimizing equipment deterioration.
Implementation Method 1
a device for metal thermal spraying, pulling means, centring means for a head for projecting particles of molten metal
Data Source
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Figure 3~4
Figure 5
AI summary
The device is formed of: a remote-controlled vehicle (1) having expandable, longitudinal rolling means; a head having sensor means and/or thermal spraying means (4) disposed on the vehicle, and which head can be suitably positioned and oriented; electrical, pneumatic and/or hydraulic connections for powering, controlling and manoeuvring the vehicle (1) and the thermal spraying device (4); and a set of expandable transverse wheels. The method comprises: introducing, positioning and moving said device forward in the duct; detecting parameters using the sensor means and/or thermally spraying metal.