Pipeline Joint Insulation Robot With Integrated Sealing and Mixing
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Solution Overview
Problem
Existing devices for internal insulation of pipeline welded joints face issues such as incomplete filling of the annular space, poor mixing quality of two-component compounds, lack of built-in dispensing equipment, temperature control, and ineffective washing and cleaning systems, leading to suboptimal insulation quality and operational inefficiencies.
Innovation Solution
A robotic device with a sealing unit, compound feeding unit, and pneumatic automation system that includes a cylindrical casing with a radially expandable actuator, static mixer, and integrated dosing and washing systems, enabling automated sealing, compound delivery, mixing, and quality control, as well as temperature regulation and efficient washing and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple sealing device is used without built-in dispensing equipment, then the device complexity is reduced, but the manufacturing precision and reliability of insulation are worsened due to incomplete filling of annular space
Solution Approach 1:
The patent combines the sealing device and compound dispensing equipment into a single integrated unit. The dispensing nozzle is positioned within the sealing device, allowing simultaneous sealing and filling operations. This merging ensures complete filling of the annular space while maintaining device compactness and operational efficiency.
Solution Approach 2:
The sealing device is designed to perform multiple functions: sealing the annular space, dispensing compound, evacuating air, and controlling the insulation process. This multi-functionality eliminates the need for separate equipment, reducing overall system complexity while ensuring high manufacturing precision through coordinated operations.
2Device complexity
If compound is delivered through a single channel, then the device complexity is reduced, but the productivity is worsened due to incomplete filling when air pressure equals compound injection pressure
Solution Approach 1:
The compound delivery system is segmented into multiple independent channels (at least two channels) that can deliver compound simultaneously or sequentially. This segmentation allows continuous filling of the annular space even when one channel encounters pressure resistance, ensuring complete filling and high productivity while maintaining manageable device complexity.
Solution Approach 2:
The patent introduces an intermediary air evacuation system that removes air from the annular space during compound filling. This mediator (vacuum or gas evacuation mechanism) reduces air pressure resistance, allowing compound to flow more easily through the delivery channels and complete the filling process efficiently.
3Device complexity
If no static mixer is used for compound delivery, then the device complexity is reduced, but the manufacturing precision is worsened due to poor mixing quality of two-component compounds
Solution Approach 1:
The static mixer is nested within the compound delivery system, with mixing elements integrated into the delivery channels or nozzle structure. This nested design ensures thorough mixing of two-component compounds before they reach the annular space, guaranteeing high manufacturing precision while avoiding the need for separate external mixing equipment.
4Device complexity
If no temperature control system is implemented, then the device complexity is reduced, but the adaptability is worsened due to inability to operate across various temperatures
Solution Approach 1:
The patent employs pneumatic or hydraulic heating/cooling elements integrated into the device structure. Fluid circulation channels are incorporated to deliver heated or cooled fluid to temperature-sensitive components, enabling operation across various temperatures without significantly increasing device complexity.
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 device ensures high-quality, full-cycle monolithic insulation of pipeline welded joints with improved efficiency, reliability, and reduced human intervention, capable of operating across various temperatures and environments, including underground and underwater pipelines.
Implementation Method 1
The actuator is pressurized inside, the actuator is radially expanded, and the shell is pressed against the protective busing and the surfaces of the joined pipes
Implementation Method 2
A third short, curved tube connecting these two tubes to the nozzle is connected to the point of the two tubes connection. The short, curved tube serves as a static mixer.
Implementation Method 3
The two components of the two-component compound are fed into the device inner cavity through two tubes. The compound components enter a short, curved tube in the immediate vicinity of the device center, and there they are combined into one flow.
Implementation Method 4
Compressed air is pumped into the device inner cavity. The peripheral parts of the elastic shell inflate and press against the pipeline inner surface. Annular space is created between the outer surface of the elastic shell central part and the inner surface of the pipeline insulated part.
Implementation Method 5
The two components of the two-component compound are fed into the device inner cavity through two tubes. The released mixture fills the annular space cavity and hardens.
Implementation Method 6
When the compound polymerization process is completed, the pressure inside the actuator is decreased, the shell is disconnected from the protective bushing and the inner surfaces of the connected pipes
Data Source
AI summary
A pipeline construction usable for internally insulating a welded joint between pipes with an internal protective coating. A device for internally insulating a welded pipeline joint includes a sealing assembly including a cylindrical housing and a coaxially-fastened cylindrical working member that radially expands upon generation of excess pressure in a cavity thereof. Inside the housing are a sealing compound feed assembly, a dosing device formed by a piston assembly for sealing compound components, and a pneumatic control assembly. In the dosing device, working cavities for each component are connected to the feed assembly. The elastic working member has a conduit connected to the feed assembly for feeding sealing compound into an annular gap in a welded joint region, and a conduit for pumping air out of the gap. The pneumatic control assembly controls dosing device and feed assembly functioning and generates excess air pressure in the working member cavity.