Automated Pipe Alignment Using Multi-Plane Optical Measurement
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Solution Overview
Problem
Conventional pipe measurement and alignment systems are labor-intensive, prone to operator error, and require extensive training, with long cycle times and limited accuracy, making them inconsistent and inefficient for precision machining operations, especially in field conditions.
Innovation Solution
An automated method using a measurement sensor mounted to a portable machining system that automatically moves around a pipe end in multiple planes to generate data sets, processing them to determine the center and axis, allowing for automatic alignment without manual intervention, reducing operator reliance and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional dial indicator measurement methods are used, then operator flexibility and adaptability to field conditions are maintained, but measurement precision, consistency, and alignment accuracy deteriorate due to operator error and subjectivity
Solution Approach 1:
The patent replaces manual mechanical dial indicator measurement with an automated optical measurement system using lasers and cameras. The system captures images of the pipe end and uses image processing algorithms to automatically determine center position and alignment, eliminating operator subjectivity and improving measurement precision while maintaining portability for field conditions.
Solution Approach 2:
The system creates an optical copy (image) of the pipe end geometry and processes this digital representation to determine alignment parameters. By working with image data rather than manual measurements, the system achieves higher precision and consistency without requiring complex mechanical measurement apparatus.
2Productivity
If manual dial indicator rotation and reading methods are used, then equipment simplicity is maintained, but productivity and measurement speed deteriorate due to time-consuming iterative alignment processes
Solution Approach 1:
The system performs preliminary alignment by capturing multiple images of the pipe end at different orientations before final machining. The processor analyzes these pre-captured images to calculate center position and alignment parameters, eliminating the need for time-consuming iterative adjustments during the alignment process itself.
Solution Approach 2:
The measurement system automatically processes its own captured images to determine alignment parameters without requiring operator intervention for reading dial indicators or calculating positions. The system self-calculates center position, radius, and alignment angles from the image data, dramatically reducing cycle time.
3Reliability
If automated measurement systems are implemented, then measurement precision and consistency improve, but device complexity and initial setup requirements worsen
Solution Approach 1:
The system uses a multi-functional portable apparatus that combines machining capabilities with integrated optical measurement functions. The same portable machine that performs counterboring also houses the laser source, camera, and processing unit, eliminating the need for separate complex measurement equipment and reducing overall system complexity while maintaining high reliability.
4Ease of operation
If automated image-based measurement is used, then operator training requirements are reduced, but measurement system complexity increases
Solution Approach 1:
The system automatically performs all measurement and calculation functions without requiring operator expertise in manual alignment techniques. The processor autonomously analyzes captured images, calculates center positions, determines alignment parameters, and guides the machining operation, making the system easy to operate while incorporating sophisticated measurement technology.
Data Source
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AI summary
A method (20) of aligning a portable machining system (100) to a pipe end portion (106) includes automatically moving a measurement sensor (128) mounted to the portable machining system (100) about the pipe end portion (106) in a first measurement plane (132) to generate a first set of measurement data. The method includes translating the measurement sensor (128) from the first measurement plane (132) to a second measurement plane (134). The method includes automatically moving the measurement sensor (128) about the pipe end portion (106) in the second measurement plane (134) to generate a second set of measurement data and processing the first and second sets of measurement data with a processing module (109) to determine a center and an axis of the pipe end portion (106).