Mechanical Pig Pusher for Safe Pipeline Launcher Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Handling large pipeline pigs during launch insertion is hazardous for workers due to manual handling, which can lead to injuries and accidents, especially when dealing with pressurized vessels and heavy equipment.
Innovation Solution
A mechanical pig pusher device comprising a metal support structure with adapter and keeper pins, attachable to heavy equipment, that mechanically aligns and pushes the pig into the launcher, eliminating the need for manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling is used to insert large pipeline pigs into the launcher, then the operation can be performed with simple equipment, but worker safety is compromised due to risk of injury from heavy objects and pressurized vessels
Solution Approach 1:
A mechanical pig pusher device serves as an intermediary tool between the worker and the heavy pipeline pig. The device includes a pusher mechanism with a pusher plate that contacts the pig, transferring force from the hydraulic system to the pig without requiring direct worker contact. This intermediary mechanism eliminates the safety hazard of manual handling while maintaining operational capability.
Solution Approach 2:
The patent replaces the manual mechanical handling system with an automated hydraulic mechanical system. The pig pusher is driven by a hydraulic motor that rotates a spool, which in turn drives a cam mechanism to move the pusher plate forward. This substitution of manual mechanical operations with automated hydraulic-mechanical systems improves safety while performing the necessary function.
2Productivity
If manual handling of large pigs is performed, then equipment cost is minimized, but productivity is reduced due to the need for multiple workers and manual coordination
Solution Approach 1:
The pig pusher device is designed to perform the insertion operation autonomously once positioned. The hydraulic system automatically sequences the operations: the spool rotates, the cam mechanism activates, the pusher plate moves forward to push the pig, and then retracts. This self-service capability eliminates the need for multiple workers to manually coordinate the insertion, significantly improving productivity.
Solution Approach 2:
The patent employs dynamic mechanical elements including a rotating spool that converts rotational motion to linear motion through a cam mechanism. The pusher plate moves dynamically along the spool axis, engaging and pushing the pig only when needed, then retracting automatically. This dynamic operation allows a single operator to control a sophisticated device that performs complex insertion tasks efficiently.
3Object-affected harmful factors
If a mechanical pig pusher is implemented to eliminate manual handling, then worker safety is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The pig pusher device is segmented into distinct functional components: a hydraulic motor, a spool assembly, a cam mechanism, a pusher plate, and a mounting bracket. Each component performs a specific function and can be manufactured separately using standard machining processes. This segmentation allows for easier manufacturing and assembly while maintaining the overall safety function of eliminating manual handling.
Data Source
AI summary
A mechanical device that is used to prevent injury to workers that are handling pigs during launch insertion into a pipe. The mechanical device is attached to a large piece of construction equipment so that workers do not have to handle the pig.