Pipe Expansion Wall Thickness Measurement for Leak-Safe Tube Sheets
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Solution Overview
Problem
Existing methods for verifying the quality of pipe assemblies in pipe sheet holes fail to accurately assess the wall thickness reduction and plastic deformation, leading to potential leaks and impractical repair processes.
Innovation Solution
A method and system for determining wall thickness reduction (%WR) using initial and final pipe diameters, combined with imaging and computer analysis, to ensure plastic deformation of pipes remains below the critical breakage point and maintains pipe durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expansion process is performed to achieve sufficient tightness between pipe and plate, then sealing quality is improved, but wall thickness reduction increases leading to potential pipe breakage
Solution Approach 1:
The patent performs preliminary measurement of the initial inner diameter of the pipe before expansion using an imaging device. This allows establishing a baseline reference value that will be used later to calculate wall thickness reduction, enabling quality control before the expansion process alters the pipe dimensions
Solution Approach 2:
The patent implements a feedback mechanism by measuring the final inner diameter of the pipe after expansion, comparing it with the initial measurement, and calculating the wall thickness reduction percentage. This feedback loop enables determination of whether the expansion process maintained adequate pipe strength while achieving sufficient sealing
2Reliability
If traditional leakage testing is performed after assembly, then leak detection is achieved, but quality verification of pipe deformation is insufficient and repair is impractical
Solution Approach 1:
The patent replaces traditional mechanical leakage testing with an imaging-based measurement system. By using an imaging device to capture images of the pipe and calculating wall thickness reduction based on diameter measurements, the system provides quantitative quality verification that goes beyond simple leak detection, enabling assessment of pipe deformation quality
Solution Approach 2:
The patent introduces an intermediary calculation process that determines wall thickness reduction percentage by comparing initial and final inner diameter measurements. This intermediary metric serves as a proxy for assessing both sealing quality and pipe structural integrity, providing comprehensive quality verification without requiring physical repair access
3Measurement precision
If precise measurement of pipe dimensions is performed to calculate wall thickness reduction, then quality control accuracy is improved, but measurement complexity and time increase
Solution Approach 1:
The patent extracts only the essential measurement information needed for quality control by using an imaging device to capture images of the pipe and automatically calculating the inner diameter through image analysis. This extraction approach obtains precise dimensional data without requiring complex manual measurement procedures, maintaining accuracy while reducing measurement time
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
Enables quick, reliable, and safe quality control of pipe assemblies, ensuring adequate seal integrity and durability by measuring wall thickness reduction through triangulation and image analysis, reducing the risk of leaks.
Implementation Method 1
an act of capturing a first image of the pipe sheet with the pipe(s) inserted in the pipe sheet hole(s) before expansion, and from the first image determining: an initial inner diameter of pipe before expansion, an outer diameter of pipe before expansion, an inner diameter of pipe sheet hole, and capturing a second image of the pipe sheet with the pipe(s) inserted in the pipe sheet hole(s) after expansion
Data Source
AI summary
A method of determining a wall thickness reduction, % WR of a pipe fixed in a pipe sheet hole in a pipe sheet by expansion is provided. The method includes an act of receiving initial inner diameter of pipe before expansion, outer diameter of pipe before expansion, inner diameter of pipe sheet hole and final inner diameter of the pipe after expansion, and an act of determining the wall thickness reduction, % WR of the pipe based on the received diameters. An imaging system for performing the method and a use of the method is also provided.