Pipe End Deformation Ring for Precise Alignment Before Welding
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Solution Overview
Problem
The current process of positioning and attaching large diameter pipes, such as oilfield pipes, is time-consuming, costly, and hazardous, requiring many workers and expensive equipment, and lacks efficient methods for aligning and securing pipe ends for welding or other securement.
Innovation Solution
A pipe processing tool that deforms the ends of pipes to match their circumferential shapes, allowing for automated or manual alignment and processing, including welding, using sensors and deformation rings with actuatable pipe deformation members, controlled by a single operator from the ground, with the option for manual override.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual pipe positioning and alignment methods are used, then workers have direct control over pipe alignment, but the process is extremely time-consuming and requires many workers and expensive equipment
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated system that uses sensors (optical/electromagnetic fields) to detect pipe end geometries and a control system to operate deformation members. This substitution of mechanical manual operations with automated sensing and control systems directly increases productivity while managing equipment complexity through integration.
Solution Approach 2:
The pipe end deformation members automatically adjust and deform pipe ends to matching geometries through automated control based on sensor feedback. The system performs self-adjustment without continuous manual intervention, allowing rapid pipe attachment while reducing the need for multiple workers and complex manual positioning equipment.
2Ease of operation
If automated pipe alignment and processing is implemented, then single-operator control improves safety and reduces labor requirements, but the system complexity and initial cost increase
Solution Approach 1:
The pipe processing tool integrates multiple functions including sensor detection, automated deformation member control, and pipe end matching capabilities into a single multi-functional device. This allows one operator to control alignment, deformation, and processing operations, improving safety and ease of operation while managing system complexity through functional integration.
Solution Approach 2:
The system uses sensors to detect pipe end geometries and provides feedback to the control system, which automatically adjusts deformation members to achieve matching pipe end shapes. This closed-loop feedback mechanism enables precise automated control with minimal operator intervention, improving safety while managing complexity through intelligent control algorithms.
3Manufacturing precision
If pipe ends are deformed to match circumferential shapes, then alignment precision for welding is improved, but additional processing time and equipment are required
Solution Approach 1:
The system performs preliminary deformation of pipe ends to predetermined matching geometries before the welding or attachment operation. By pre-shaping pipe ends to compatible configurations, the system ensures precise alignment is achieved automatically, improving manufacturing precision while the integrated automation minimizes the additional time required through efficient sequential operations.
Solution Approach 2:
Manual alignment and fitting operations are replaced with automated sensor-based detection and controlled deformation of pipe ends. This substitution enables precise circumferential shape matching through automated control, improving alignment precision while the efficiency of automated operations offsets the additional processing time through reduced manual intervention requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces the time and cost of pipe attachment processes, enhances worker safety by allowing single-operator control of pipe alignment and processing, and improves the efficiency of pipe laying and attachment operations.
Implementation Method 1
Each of the pipe deformation members comprises a fluid actuated piston that is actuatable in a radial direction toward and away from the center of the first deformation ring
Implementation Method 2
One or more sensors, such as laser sensors, detect the circumferential shape of at least one of the pipe ends
Data Source
AI summary
A pipe processing tool that is configured to deform the end of a pipe so that the circumferential shape of the end of the pipe generally matches the circumferential shape of an adjacent pipe end. Matching the circumferential shapes of the pipe ends is advantageous during a pipe attachment process. The pipe processing tool can include a deformation ring with a plurality of pipe deformation members. Each pipe deformation member faces radially inward and is actuatable in a radial direction toward and away from the center of the deformation ring in order to permit engagement with the pipe. Each pipe deformation member is individually and separately actuatable from the other pipe deformation members so that the circumferential shapes of the pipes can be altered by controlling suitable ones of the pipe deformation members.