Pipe Weld Removal Tool for Uniform Shipboard Flow Surfaces
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Solution Overview
Problem
Existing methods for repairing degraded shipboard piping systems, such as base metal repair (BMR), result in excess weld material that requires manual machining, leading to inconsistent results due to human error and the limitations of large traditional machines in cramped shipboard spaces, especially when dealing with components like valves, elbows, and tees.
Innovation Solution
A compact tool that mounts on the outside surface of pipes and components, using support plates and graduated scales to ensure consistent positioning, with a bearing system to secure a bur tool for uniform removal of excess weld material on interior, exterior, and bevel surfaces, accommodating various piping configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual machining is used to remove excess weld material, then the process can be performed in confined shipboard spaces, but the results are inconsistent due to human error
Solution Approach 1:
The tool automatically maintains the correct cutting depth through its mechanical design featuring a support plate that contacts the pipe exterior and a scale-marked rod that limits the bur tool's penetration depth, eliminating the need for continuous operator measurement and adjustment
Solution Approach 2:
The invention replaces manual operator control with a mechanical constraint system where the support plate and scale-marked rod create a fixed geometric relationship between the tool and pipe, substituting human skill with mechanical precision
2Manufacturing precision
If traditional large machines are used for end preparation, then manufacturing precision can be achieved, but the devices cannot be used in cramped shipboard spaces
Solution Approach 1:
The tool divides the end preparation function into separate modular components: a support plate for exterior contact, a scale-marked rod for depth measurement, and a bur tool for cutting, allowing each component to be small while maintaining overall precision
Solution Approach 2:
The tool transitions from traditional 3-axis machine control to a 2-dimensional constraint system where the support plate contacts the pipe exterior and the scale-marked rod provides the third dimension of depth control, enabling precision in a compact form
3Ease of manufacture
If hand machining is performed on piping components, then the process can be completed on-site, but the results violate minimum wall thickness requirements due to inconsistency
Solution Approach 1:
The scale-marked rod provides continuous visual feedback on the cutting depth, allowing the operator to see the remaining distance to the desired depth and adjust accordingly, ensuring consistent results
Solution Approach 2:
The support plate is positioned and contacted against the pipe exterior before the cutting operation begins, pre-establishing the reference plane from which all subsequent depth measurements are taken
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
Ensures uniform surface preparation with reduced human error, achieving consistent dimensions and unobstructed flow by precisely removing excess weld material on pipes, valves, and elbows, even in confined shipboard spaces.
Implementation Method 1
a bearing system to secure a bur tool for uniform removal of excess weld material on interior, exterior, and bevel surfaces
Data Source
AI summary
Base metal repairs are necessary to maintain the integrity of the interior flow within piping systems aboard ships. As fluids travel through piping internal degradation of the piping occurs and must be repaired to ensure that the flow remains uninterrupted. Additional material is added to correct the problem by welding; however, the excess weld material must be removed to ensure uniform flow through the piping system. The excess weld material must be removed, and this tool has been designed to remove the excess weld material to produce a uniform result.