Inductive Sensor Control for Underwater Pipe S-Z Assembly
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Solution Overview
Problem
The existing methods for assembling peripheral elements in an S-Z configuration around a central flexible core in pipe production are complex and prone to mechanical damage due to incorrect positioning, especially under varying temperatures, leading to unreliable manual control and increased production costs.
Innovation Solution
A method utilizing inductive sensors to synchronize with the central flexible core's movement, acquiring measurement signals to control the positioning of peripheral elements, and processing these signals to ensure the S-Z configuration meets predetermined tolerance thresholds, with visual and audible alarms triggered for defective parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual control method is used to check helix angle, then production line can be monitored, but reliability of control is low and production is interrupted regularly
Solution Approach 1:
The patent replaces the manual visual inspection system with an automated optical measurement system. The system uses a camera to capture images of the pipe and peripheral elements, then processes these images computationally to measure the helix angle and verify S-Z configuration. This substitution eliminates human visual acuity limitations and concentration variability, providing continuous automated control without interrupting production.
Solution Approach 2:
The patent implements a feedback control system where the optical measurement continuously monitors the positioning of peripheral elements during production. The measured helix angle and S-Z configuration parameters are compared against predetermined tolerance thresholds, and corrective feedback is provided to maintain positioning accuracy. This closed-loop feedback ensures high reliability while maintaining continuous production.
2Strength
If S-Z configuration assembly is performed, then mechanical strength and fatigue resistance are improved, but positioning precision becomes critical and complex
Solution Approach 1:
The patent replaces manual measurement tools with an automated optical measurement system that uses digital image processing to precisely determine the helix angle and S-Z configuration. This system automatically calculates positioning parameters from captured images, eliminating manual measurement errors and ensuring consistent precision throughout production without increasing operational complexity.
Solution Approach 2:
The patent transforms the physical positioning problem into a measurable parameter problem by using optical imaging to capture geometric parameters. The system measures the helix angle, pitch, and reversals of the S-Z configuration as quantitative parameters, allowing precise control and verification of peripheral element positioning to ensure mechanical integrity.
3Stability of the object's composition
If adhesive tapes are applied to retain peripheral elements, then element positioning is secured, but adhesive power is affected by temperature variations
Solution Approach 1:
The patent performs preliminary verification of the S-Z configuration and peripheral element positioning using the optical measurement system before the adhesive tapes are applied. By ensuring correct positioning is achieved during the assembly process itself, the system reduces reliance on adhesive tapes for positioning control, making the assembly more stable and less sensitive to temperature variations that affect adhesive performance.
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
This method enhances the reliability of S-Z configuration assembly, reducing mechanical damage and production costs by providing real-time, automatic control of peripheral element positioning, ensuring the integrity of the pipe.
Implementation Method 1
providing at least one inductive sensor adapted to rotate about said central flexible core in a manner synchronized with the longitudinal movement of said central flexible core so that said at least one sensor scans the periphery of said central flexible core opposite and in the immediate proximity of said peripheral elements wound around said central flexible core
Data Source
AI summary
A method for producing a tubular underwater pipe including: assembling a structure of peripheral metal elements (3A, 3B, 3C) wound in an S-Z configuration about a central flexible core (1) as the core is driven in movement along its longitudinal axis; providing an inductive sensor (12) arranged for rotation about the central flexible core (1) in a manner synchronized with the longitudinal movement of the core so that the sensor scans the periphery of the structure opposite and in the immediate proximity of peripheral elements wound about the core and during the assembly step; using the sensor (12) to acquire measurement signals (S) of which the amplitude varies according to whether or not the sensor (12) is located opposite a peripheral element during the rotation of the sensor (12); and using the measurement signals to control the positioning of the assembled peripheral elements.