Pipe Bevel Alignment Using Machine-Readable Codes for Faster Welding
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Solution Overview
Problem
Current pipe welding methods in offshore pipeline laying, particularly during S-lay operations, face challenges in achieving high-quality welds due to manual alignment processes, which are time-consuming and prone to errors, leading to poor alignment and increased costs.
Innovation Solution
A method utilizing machine-readable codes on the pipes to scan and align the bevelled ends, allowing for precise relative movement calculations to achieve optimal alignment, reducing the need for extensive scanning and improving alignment accuracy through a control unit that adjusts pipe handling equipment for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment process is used, then alignment can be performed with simple equipment, but alignment time is excessive and accuracy is poor
Solution Approach 1:
The patent replaces manual visual alignment with an automated optical measurement system. A scanner reads machine-readable codes (e.g., barcodes) on pipe surfaces to automatically determine pipe positions and orientations, eliminating the need for manual measurement and calculation while significantly improving alignment accuracy and reducing time.
Solution Approach 2:
The system enables pipes to self-identify their positions and orientations through machine-readable codes attached to their surfaces. The control unit automatically processes this information to calculate alignment parameters, allowing the system to perform alignment functions autonomously without extensive human intervention.
2Manufacturing precision
If extensive scanning of pipe surfaces is performed, then alignment accuracy is improved, but processing time increases
Solution Approach 1:
The patent extracts only the essential alignment information from pipe surfaces by reading machine-readable codes, rather than scanning entire pipe surfaces. The codes contain pre-encoded position and orientation data, allowing the system to obtain all necessary alignment parameters from specific code locations without examining the whole pipe surface.
Solution Approach 2:
Machine-readable codes are pre-attached to pipe surfaces at specific locations during manufacturing, containing all necessary alignment information in advance. This preliminary encoding eliminates the need for time-consuming surface scanning during alignment operations, as the data is already prepared and readily accessible.
3Manufacturing precision
If visual measurement by human operator is used, then equipment complexity is low, but alignment accuracy and consistency are poor
Solution Approach 1:
The patent replaces human visual measurement with an automated optical scanning system that reads machine-readable codes. This substitution eliminates human error and subjectivity while providing consistent, repeatable measurements. The system uses standard barcode scanning technology integrated with control unit software to automatically calculate alignment parameters.
4Productivity
If pipe alignment is performed under tension load, then pipeline laying can proceed, but alignment accuracy deteriorates due to deformation
Solution Approach 1:
The system performs multiple sequential scans of pipe positions and orientations during the alignment process. The control unit compares measured values with target values and automatically adjusts pipe positions through the handling equipment. This closed-loop feedback control ensures accurate alignment even under tension load by continuously monitoring and correcting for deformation.
Solution Approach 2:
The patent employs dynamic alignment measurement and adjustment rather than static single-point measurement. The scanner and handleing equipment can move to capture pipe positions at different stages of the alignment process, allowing the system to adapt to changing pipe configurations under load and achieve accurate final alignment.
Data Source
Figure 1a~1b
Figure 1c~1e
Figure 2
AI summary
A method of aligning a first pipe (22) and a second pipe (50) end-to-end in a position ready for welding. The pipes (22, 50) each have an end bevelled with a shape which has been scanned and stored in memory of a control unit (70). In one aspect, at least one of the pipes (22, 50) has a plurality of machine readable codes (60) located at positions distributed around their circumference of the pipe (22, 50). The method comprises the steps of: effecting relative movement of the ends of the first and second pipes (22, 50) towards each other, reading at least one of the codes (60) with a reader (72), and ascertaining the relative movement required to align the pipes (22, 50) in accordance with a target orientation. The relative movement is ascertained with the use of information provided by the code read (60) by the reader (72) and the shapes of the bevelled ends of the pipes (22, 50) stored in the memory of the control unit (70). According to other aspects, a closed loop control method and machine- learning may be used to align the pipes (22, 50). A pipe-laying vessel (20) comprising pipe handling equipment and the control unit (70) is also provided.