Pipe Coating Removal for Precise Field Joint Chamfering
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Solution Overview
Problem
The existing processes for preparing pipeline field joints for coating are inefficient and require manual labor for machining and chamfering, which can lead to inconsistencies and increased costs.
Innovation Solution
A pipe coating material removal apparatus with a support frame and subframe that rotates around the pipe, equipped with adjustable coating material removal members such as milling cutters and grinding wheels, allowing for automatic removal of coating material at various angles and depths to create chamfers or clean surfaces, assisted by sensors for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual power tools are used to remove coating material and create chamfers, then the process is simple and requires minimal equipment, but the preparation quality is inconsistent and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical power tools with an automated mechanical system that rotates around the pipe. The apparatus uses a rotating subframe with coating removal members (milling cutters, grinding wheels, or abrasive devices) that are automatically positioned and controlled to remove coating material and create chamfers with consistent precision, eliminating the inconsistency of manual operations.
Solution Approach 2:
The apparatus is designed to be self-positioning and self-regulating through its rotating subframe mechanism. The subframe rotates around the pipe and automatically brings the coating removal members into contact with the coating material at the correct locations, maintaining consistent preparation quality without requiring continuous manual adjustment.
2Productivity
If automated apparatus is used to remove coating material, then productivity and consistency are improved, but the device complexity increases
Solution Approach 1:
The apparatus is divided into distinct functional segments: a support frame for stability, a rotatable subframe for positioning, and multiple coating removal members (milling cutters, grinding wheels, or abrasive devices) for different removal needs. This segmentation allows each component to perform its specific function efficiently, improving overall productivity while keeping the design modular and manageable.
Solution Approach 2:
The rotating subframe with multiple types of coating removal members can perform multiple functions: removing thick coating material (milling), smoothing surfaces (grinding), and creating chamfers (abrasive devices). This multi-functionality increases productivity by eliminating the need for multiple separate tools or operations, while the modular design keeps the overall apparatus complexity controlled.
3Loss of time
If manual machining is used for field joint preparation, then the equipment cost is low, but the labor time and cost increase
Solution Approach 1:
The apparatus enables continuous coating removal and chamfering operations through its rotating subframe mechanism. As the subframe rotates around the pipe, the coating removal members continuously work on the coating material without interruption, significantly reducing preparation time compared to manual machining where tools must be repeatedly positioned and operated.
Solution Approach 2:
The apparatus performs preliminary coating removal and chamfering actions automatically before the coating application process begins. The rotating subframe pre-prepares the field joint surfaces by removing coating material and creating the necessary chamfers, ensuring that the surfaces are ready for coating application without requiring subsequent manual preparation steps.
Data Source
AI summary
A pipe coating material removal apparatus, comprising a support frame, a subframe, and one or more coating material removal members. The subframe is supported by the support frame and is configured to rotate relative to the support frame at least partially around a subframe rotation axis. The subframe rotation axis is configured to be substantially coaxial with a longitudinal axis of a pipe to which the apparatus may be applied in use. The, or each, coating material removal member is rotatably mounted to the subframe to remove part of an exterior coating of a pipe. The apparatus is configured such that the one or more coating material removal members enable the removal of pipe coating material at orientations substantially parallel to, and inclined with respect to, the longitudinal axis of the pipe.