Pipe Setter Feedback Control for Accurate Line and Grade
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Solution Overview
Problem
The construction of underground pipes often faces challenges in achieving accurate alignment and grade due to the use of flexible PVC pipes, which can lead to misalignment and deformation, resulting in increased construction costs, delays, and maintenance issues, as well as the need for on-site surveyors and third-party inspectors to verify each pipe installation.
Innovation Solution
A pipe setting system comprising a pipe setter device mounted inside the pipe, equipped with electronic components such as a 2D sensor, magnetic compass, and Wi-Fi transmitter, which allows real-time monitoring and data transmission to ensure accurate installation according to design plans, eliminating the need for on-site surveyors and enabling immediate as-built plan preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional offset staking and manual pipe installation methods are used, then construction procedures are simple and equipment requirements are minimal, but pipe alignment accuracy and grade precision deteriorate due to flexible pipe deformation
Solution Approach 1:
The patent applies preliminary action by pre-establishing a survey control network and setting reference markers before pipe installation begins. The mounting hull is pre-configured with sensors and positioning systems that automatically track pipe alignment and grade during installation, eliminating the need for complex manual measurements after each pipe segment is placed.
Solution Approach 2:
The patent implements feedback through real-time monitoring systems that continuously measure pipe alignment and grade using sensors mounted on the hull. The system provides immediate feedback to operators, allowing corrections to be made during installation rather than discovering errors after completion, thus maintaining high precision without complex procedures.
2Measurement precision
If surveyors and third-party inspectors are deployed to verify each pipe installation, then pipe installation accuracy is improved, but construction costs and time consumption increase
Solution Approach 1:
The patent applies self-service by equipping the mounting hull with autonomous measurement and verification systems. The hull itself performs the inspection function through integrated sensors, GPS receivers, and data processing capabilities that automatically verify pipe alignment and grade without requiring external surveyors or inspectors, thereby maintaining measurement precision while eliminating productivity losses.
Solution Approach 2:
The mounting hull serves multiple functions simultaneously: it provides structural support for the pipe, incorporates sensors for alignment measurement, includes GPS for position tracking, and contains data processing equipment for real-time verification. This multi-functionality consolidates what would traditionally require separate surveying equipment and personnel into a single integrated system.
3Area of stationary object
If deep and narrow trenches are excavated to minimize construction impact in developed areas, then surface disruption is reduced, but the difficulty and time required for accurate conduit installation increases
Solution Approach 1:
The patent replaces manual mechanical measurement methods with electronic sensing and automated positioning systems. The mounting hull incorporates sensors, GPS receivers, and computer processing that automatically calculate and verify pipe alignment and grade, eliminating the need for manual surveying operations that would be particularly difficult in narrow trenches.
Solution Approach 2:
The mounting hull acts as an intermediary device between the pipe and the measurement system. It provides a stable platform that carries sensors and positioning equipment directly on the pipe being installed, allowing accurate measurements to be taken even in constrained trench environments where traditional surveying equipment would be difficult to deploy.
4Reliability
If PVC pipes are used for their corrosion resistance, then durability is improved, but pipe alignment stability deteriorates due to flexible pipe deformation at joints
Solution Approach 1:
The patent implements feedback by continuously monitoring pipe alignment during installation using sensors mounted on the hull. The system detects deviations caused by flexible pipe behavior at joints and provides real-time feedback to operators, allowing immediate corrections to be made while the pipe is still being installed, rather than discovering misalignment after the fact.
Solution Approach 2:
The system applies preliminary action by pre-configuring the mounting hull with sensors and positioning systems that track pipe alignment from the beginning of installation. Reference markers and control points are established before pipe laying begins, creating a baseline against which all subsequent pipe segments are measured and adjusted to maintain alignment stability.
Data Source
AI summary
The invention is embodied in a construction quality control tool that allows owners and contractors to meet design plans and specifications. It saves time and costs to both parties' budgets by easily measuring pipe grading while eliminating need for surveyors on site and quickly transmitting print data in real time for third-party inspectors to prepare as-built plans. Most importantly, it ensures pipes are installed safely and accurately to prevent construction issues in the future.The preferred embodiment of the invention comprises two devices: (1) a pipe setter and (2) a remote processing and recording unit. The pipe setter is mounted inside the new pipe to be installed. The pipe setter helps the pipe installer reliably and accurately install pipe that matches the line and grade (fixed x, y z) per design plan. The remote processing and recording unit enables the construction superintendent and the third-party inspector monitoring the pipe installation in real time.