Variable-Height Pipe Crawler for Lower-Energy Diameter Adaptation
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Solution Overview
Problem
Conventional pipe crawlers require oversized motors to accommodate different pipe diameters, leading to increased energy requirements and larger cables, resulting in an upward spiraling energy demand.
Innovation Solution
The use of actuatable legs that extend wheels to various positions for different pipe diameters, combined with independent hub motors, allows for optimal motor sizing for a single wheel size, reducing energy requirements and cable size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional crawlers use wheels of different diameter to adapt to pipes of different diameter, then the device can accommodate various pipe sizes, but the motor must be oversized to accommodate the largest wheel size, leading to increased energy requirements and larger cables
Solution Approach 1:
The patent applies the dynamics principle by making the wheel radius variable through an extendable leg mechanism. The leg can be extended or retracted to adjust the wheel's distance from the pipe wall, allowing the same motor size to accommodate different pipe diameters. This dynamic adjustment eliminates the need for oversized motors while maintaining adaptability to various pipe sizes.
2Adaptability or versatility
If the motor is oversized to accommodate the largest wheel size, then the device can handle all pipe sizes, but the cable size must increase to support the higher power requirements, creating an upward spiraling energy demand
Solution Approach 1:
The dynamic leg extension mechanism allows the system to optimize motor power requirements for each specific pipe size encountered. By adjusting the wheel radius to match the pipe diameter, the motor operates at appropriate power levels rather than constantly running at maximum capacity, thereby reducing cable size and overall system complexity.
3Productivity
If different sized wheels are used for different sized pipes, then the crawler can be optimized for each pipe size, but the device requires wheel interchangeability and oversized motor capacity, increasing device complexity
Solution Approach 1:
Instead of requiring physical wheel interchangeability, the patent implements a dynamic leg extension mechanism that adjusts the effective wheel radius. This single-wheel design with variable positioning eliminates the complexity of storing and swapping multiple wheel sizes while maintaining the ability to optimize for different pipe diameters during inspection operations.
Data Source
AI summary
A crawler comprising: (a) a body; (b) a camera head in or connected to said body; (c) a plurality of motorized hub assemblies; and (d) a plurality of legs, each of said plurality of legs having a first end and a distal second end, said first end being connected to said body, and said second end being connected to one of said plurality of motorized hub assemblies, wherein said legs are actuatable to define a minimum extended position and an extended position, wherein said motorized hub assemblies are close to said body in said minimum extended position, and distal from said body in said extended position.