Internal Girth Weld Coating Robots With Scan-Based Work Planning

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Solution Overview

Problem

The existing methods for coating field girth welds inside pipes are complex and require multiple sequential tasks, lacking an efficient system for coordination and resource optimization, which can lead to inconsistencies and reduced integrity of the protective coating.

Innovation Solution

A robotic crawling system comprising a scanning unit, weld grinding unit, surface roughness preparation unit, coating unit, and coating inspection unit, where the scanning unit generates a detailed work plan specifying task type, time, and location for each girth weld, optimizing resource allocation and ensuring precise execution of coating operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple sequential coating tasks are performed manually or with basic automation, then the coating process can be completed, but the coordination efficiency is low and resource allocation is suboptimal

Engineering Contradiction:

Improvecoating process efficiencyVSAvoidsystem coordination complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The coating system is divided into multiple specialized robotic devices, each performing a specific task (surface preparation, coating application, inspection). This segmentation allows each device to be optimized for its specific function while the central controller coordinates their sequential operations, resolving the contradiction between improved productivity and managed complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates sensors and controllers that provide real-time feedback on the coating process status, surface conditions, and device positions. This feedback enables dynamic adjustment of the sequential operations, optimizing resource allocation and coordination efficiency without requiring overly complex manual intervention.

Inventive Principle:

Principle #23Feedback

2Productivity

If a detailed work plan is generated for each robotic device, then resource allocation is optimized, but the planning and coordination time increases

Engineering Contradiction:

Improveresource allocation efficiencyVSAvoidwork plan generation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system generates comprehensive work plans for all robotic devices before the coating operation begins. The central controller pre-calculates the optimal sequence of operations, timing, and resource allocation for surface preparation, coating application, and inspection tasks. This preliminary planning eliminates during-operation delays and ensures efficient execution, resolving the contradiction between detailed resource allocation and planning time.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If multiple robotic devices operate simultaneously inside the pipe string, then the coating process is accelerated, but the risk of operational conflicts and inconsistencies increases

Engineering Contradiction:

Improvecoating process speedVSAvoidcoating integrity consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system coordinates multiple robotic devices to operate in a continuous, synchronized sequence within the pipe string. The central controller ensures that surface preparation, coating application, and inspection devices operate without interruption and in the correct sequence, maintaining continuous useful action while preventing operational conflicts. This ensures both accelerated processing and consistent coating integrity.

Inventive Principle:

Principle #20Continuity of useful action

4Manufacturing precision

If the scanning unit generates comprehensive work plans with task type, time, and location specifications, then execution precision is improved, but the processing load on the scanning unit increases

Engineering Contradiction:

Improvetask execution precisionVSAvoidscanning unit processing energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The scanning unit acts as an intermediary that collects pipe geometry and weld location data, then generates work plans that are transmitted to centralized controllers for each robotic device. This intermediary role allows the scanning unit to provide precise location and task specifications without bearing the full processing load of real-time coordination, distributing the computational energy requirements across the system architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11344974B2Optimized method and system for internal coating of field girth welds

Publication Date: 2022.05.31 SAUDI ARABIAN OIL CO

AI summary

A system for performing multiple operations on one or more weld joints of a pipe string includes a robotic scanning device that is configured to controllably travel inside of the pipe string and detect, scan and uniquely identify each weld joint within the pipe string. The system further includes a plurality of secondary robotic devices that are each configured to controllably travel inside of the pipe string and perform one or more specific operations on the one or more weld joints of the pipe string. The robotic scanning device includes a processor that is configured to generate a work plan for the plurality of secondary robotic devices. The robotic scanning device transmits work plan commands to each of the plurality of secondary robotic devices and receive transmissions from the plurality of secondary robotic devices.