Modular AI Tube Coating for Complex Tubular Geometries
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Solution Overview
Problem
Existing methods for cleaning and coating tubulars with irregular or complex geometries are inefficient, leading to non-uniform results and prolonged processing times, particularly in large-scale configurations like shell and tube heat exchangers.
Innovation Solution
A system comprising applicator lances, cleaning and coating tools, drive assemblies, and a computing system with AI, which automatically adjusts to tubular geometries for uniform and efficient cleaning and coating, reducing manual labor and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual labor and compressed air-driven plugs with liquid are used for coating, then flexibility in handling different tubular geometries is improved, but coating uniformity and productivity deteriorate
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses controlled fluid dynamics. The robotic arm manipulates a plug that generates a liquid wedge, substituting human labor with automated fluid-mechanical action. This maintains adaptability to different geometries while achieving uniform coating through precise control of fluid flow and pressure, thereby resolving the contradiction between flexibility and coating quality.
Solution Approach 2:
The invention utilizes pneumatic and hydraulic principles by employing compressed air-driven liquid flow to create a controlled liquid wedge that propagates along the tubular interior. The system uses fluid pressure and flow control to achieve uniform coating distribution across various tubular geometries, replacing manual mechanical methods with controlled fluid dynamics to simultaneously achieve adaptability and coating uniformity.
2Reliability
If standard cleaning methods like grit blasting or hydro-lancing are used, then cleaning capability is improved, but processing time and labor requirements deteriorate
Solution Approach 1:
The patent replaces traditional mechanical cleaning methods (grit blasting, hydro-lancing) with an automated robotic system that uses controlled liquid flow and pressure. The robotic arm manipulates a plug to generate a liquid wedge that cleans the tubular interior through controlled fluid dynamics. This substitution maintains effective cleaning capability while dramatically reducing processing time and eliminating manual labor through automation.
Solution Approach 2:
The system employs self-service principles by using the liquid flow itself to perform both cleaning and coating functions. The same fluid mechanism that propels the plug forward also performs the cleaning action on the tubular interior surfaces, and subsequently deposits the coating material. This multi-functional approach reduces processing time by eliminating the need for separate cleaning and coating operations.
3Adaptability or versatility
If manual coating methods are used, then adaptability to irregular geometries is improved, but labor requirements and processing time deteriorate
Solution Approach 1:
The patent replaces manual coating operations with an automated robotic system that uses fluid-driven plug manipulation. The robotic arm can precisely position and maneuver the plug through irregular tubular geometries, adapting to complex shapes while maintaining consistent coating application. This automation eliminates manual labor requirements and reduces processing time while preserving the ability to handle irregular geometries through programmed robotic motion control.
Solution Approach 2:
The system employs dynamic principles by using a movable, flexible plug that can adapt its shape and position as it travels through irregular tubular geometries. The plug is not rigid but can deform and adjust to fit various cross-sectional shapes, allowing the automated system to maintain contact with irregular surfaces for uniform coating application while reducing processing time through continuous motion.
Data Source
AI summary
Disclosed herein are methods, devices, and systems for automatically cleaning and/or coating the interior of tubes, tubulars, tubular arrays, and/or various other arrangements of tubes (e.g., tube stacks). A system for such automatic cleaning and/or coating may include (1) one or more applicator lances configured to be inserted into an interior of one or more tubes and/or tubulars, (2) coating and/or cleaning tools fitted at the end of the one or more applicator lances, (3) a drive assembly including drive motors, alignment equipment, and instrumentation, (4) a control box including a graphical user interface (GUI) for control of the system or one or more portions thereof, and (5) a computing system, which comprises one or more computing devices or processing units, for operating the system or one or more portions thereof.