Modular Pipe Fusion Carriage With Tool-Free Multi-Size Jaws
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fusion systems for polymer pipes are inflexible and cumbersome, requiring multiple tools and inserts for different pipe sizes, making them difficult to use in tight spaces and inefficient for varying pipe spacings.
Innovation Solution
A modular carriage system with removable jaws and a combined hydraulic cylinder/guide rod assembly that allows for tool-free assembly and alignment, accommodating multiple pipe sizes without inserts, and featuring a self-contained design for easy transportation and assembly on existing pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional fusion system is used to accommodate multiple pipe sizes, then multiple inserts and tools are required, but the device complexity and weight increase
Solution Approach 1:
The carriage assembly is designed with a universal jaw structure that can accommodate multiple pipe sizes (355mm, 400mm, 450mm, 500mm, 560mm, 630mm) without requiring different inserts or tools. The jaws can be adjusted and repositioned to fit various pipe diameters, allowing a single carriage assembly to perform multiple fusion operations across different pipe sizes.
Solution Approach 2:
The carriage assembly is divided into modular components including removable jaws, guide rods, and positioning elements. This segmentation allows the jaws to be independently adjusted and reconfigured for different pipe sizes, providing versatility without requiring complete replacement of the fusion system for each pipe diameter.
2Ease of operation
If a conventional fusion system is used for tight spaces, then the spatial envelope is large, but the ease of operation in tight spaces deteriorates
Solution Approach 1:
The carriage assembly is segmented into smaller modular components that can be transported separately and assembled on-site within tight spaces. The removable jaws and guide rods can be disassembled to fit through narrow access points, then reconfigured around existing pipe structures that are already in place.
Solution Approach 2:
The carriage assembly is designed to operate in constrained three-dimensional spaces by allowing assembly around existing pipe structures. The modular components can be positioned and configured in various orientations to accommodate tight spatial constraints while maintaining fusion functionality.
3Adaptability or versatility
If multiple pipe sizes are supported with dedicated jaws for each size, then the adaptability increases, but the weight and shipping size increase
Solution Approach 1:
A single set of carriage components including jaws, guide rods, and positioning mechanisms is designed to handle multiple pipe sizes (355mm through 630mm). The universal design eliminates the need for separate dedicated jaw sets for each pipe size, significantly reducing the overall weight and shipping requirements while maintaining the ability to fuse pipes across the full size range.
4Ease of operation
If tool-free assembly is implemented for removable jaws, then the ease of operation improves, but the reliability of jaw attachment may deteriorate
Solution Approach 1:
The jaw attachment mechanism incorporates dynamic locking features that allow for tool-free assembly and removal while maintaining secure attachment during operation. The mechanism enables quick configuration changes when needed but provides robust, reliable connection when the jaws are installed and locked into position.
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
The modular carriage system reduces weight and shipping size, allows for precise alignment and increased clamping force, and enables fusion of pipes in tight spaces with reduced spatial requirements and unnecessary parts, enhancing flexibility and cost-effectiveness.
Implementation Method 1
A carriage cylinder is associated with each of at least two of the guide rods. The carriage cylinder may be mounted for reciprocal travel on its associated guide rod.
Data Source
AI summary
Modular carriage for varying spacing between ends of polymer pipe during fusion. The modular carriage includes a fixed jaw; an inner movable jaw; an outer moveable jaw and a plurality of guide rods. The fixed jaw being adapted for tool free engagement with the terminal ends of the plurality of guide rods. A carriage cylinder is associated with at least two of the guide rods and mounted for reciprocal travel along the length of its associated guide rod. The movable jaws being adapted for tool free engagement with at least two carriage cylinders for reciprocal travel therewith. A combined hydraulic cylinder/guide rod includes a guide rod with an integral guide rod piston, a cylindrical tube, and a guide rod gland on each end of the cylinder tube.