Pipeline Junction Relining With Integrated LED Seal Curing
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Solution Overview
Problem
Existing pipeline relining technologies face challenges in ensuring a tight fit at the junction between a main pipeline and a branch pipeline, require multiple radiation sources for curing, lack accuracy in seal placement, suffer from cable wear and tear, and inefficiencies in cooling and power distribution, leading to potential leakage and equipment damage.
Innovation Solution
A single light curing device with integrated LEDS and a cooling system using compressed air, coupled with a seal installation device, ensures precise seal placement and curing, reduces cable wear, and optimizes cooling and power distribution, allowing simultaneous relining of the junction and branch pipeline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate hat-shaped liner seal is installed at the junction using an inflatable bladder and centrally located light source, then the risk of leakage at the junction is reduced, but the device complexity and number of components increase
Solution Approach 1:
The patent combines the seal installation device and light curing device into a single integrated assembly. The seal installation device includes an inflatable bladder for positioning the hat-shaped liner seal and a light curing device with LED array for curing the resin-impregnated liner, eliminating the need for separate installation steps and reducing overall system complexity
Solution Approach 2:
The seal installation device serves multiple functions: it positions the hat-shaped liner seal at the junction, inflates to secure the seal in place, and simultaneously provides curing through the integrated light curing device. This multi-functional approach reduces the number of separate components needed
2Reliability
If multiple radiation sources are used for curing the liner at the junction and in the branch pipeline, then complete curing is achieved, but the device complexity and power requirements increase
Solution Approach 1:
The light curing device is divided into multiple LED modules arranged in an array around the seal installation device. Each LED module acts as an independent radiation source that can be individually controlled, allowing complete coverage of the liner at the junction and in the branch pipeline while maintaining manageable system complexity
Solution Approach 2:
The LED array is arranged in a three-dimensional configuration around the seal installation device, providing curing from multiple angles and directions simultaneously. This spatial distribution of radiation sources ensures complete curing coverage without requiring an excessive number of individual light sources
3Device complexity
If a single light curing device with integrated LEDs is used, then the device complexity and power distribution are optimized, but the illumination intensity and curing effectiveness may be reduced
Solution Approach 1:
The single light curing device is segmented into multiple LED modules arranged in an array, with each module containing multiple high-intensity LEDs. This segmentation allows the device to maintain low overall complexity while achieving high illumination intensity through the cumulative output of multiple LED elements
Solution Approach 2:
The LED array is positioned to provide localized high-intensity curing at critical areas such as the junction and branch pipeline connections. The distribution of LED modules ensures that illumination intensity is optimized where most needed while maintaining overall system simplicity
4Measurement precision
If the seal placement accuracy is improved by using a seal installation device with manipulator, then the leakage risk is reduced, but the device complexity and ease of operation decrease
Solution Approach 1:
The manipulator is equipped with sensors and control systems that automatically detect the junction position and orient the seal correctly without requiring manual intervention. The device self-adjusts to achieve accurate seal placement, reducing operational complexity while maintaining high precision
Solution Approach 2:
The manipulator includes feedback mechanisms that monitor seal position and orientation in real-time, automatically adjusting the seal placement to ensure accuracy. This closed-loop control system maintains high precision while simplifying operation through automation
5Use of energy by moving object
If compressed air is used for cooling the LED array and propelling the light curing device, then the energy efficiency is improved, but the temperature control and cooling effectiveness may be insufficient
Solution Approach 1:
Compressed air serves multiple functions: it cools the LED array through heat exchange, propels the light curing device through the pipeline, and can be used for inflating the bladder. This multi-functional use of compressed air optimizes energy efficiency while meeting all cooling and propulsion requirements
Solution Approach 2:
The system uses compressed air flow through heat exchange channels to cool the LED array, leveraging pneumatic principles for efficient heat removal. The high-velocity air flow provides effective cooling while simultaneously serving as the propulsion mechanism for moving the device through the pipeline
6Reliability
If the liner is cured by UV light or hot water/steam, then the curing effectiveness is improved, but the equipment complexity and energy consumption increase
Solution Approach 1:
The patent replaces traditional thermal curing systems (hot water or steam) with a light-based curing system using LED arrays. This substitution eliminates the need for complex thermal management equipment while maintaining effective curing through photopolymerization of the resin-impregnated liner
Solution Approach 2:
The curing process transitions from thermal parameters (temperature, steam pressure) to optical parameters (light wavelength, intensity, exposure time). This parameter change enables more efficient energy use while achieving reliable curing of the liner material
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 solution provides a secure, efficient, and accurate relining process that minimizes leakage risks, reduces equipment wear, and optimizes cooling and power usage, ensuring a seamless and durable pipeline connection.
Implementation Method 1
The light curing device comprises an array of light emitting diodes (LEDs) arranged in a circular pattern around the longitudinal axis
Implementation Method 2
The liner includes a resin which is curable by exposure to electromagnetic radiation of a specific wavelength or a specific wavelength range
Implementation Method 3
The housing defines a cooling system with a cooling fluid inlet adapted for receiving a stream of cooling fluid and a cooling fluid outlet for discharging the stream of cooling fluid
Data Source
Figure 1A
Figure 1B
Figure 2A~2D
AI summary
An assembly for relining a junction between a branch pipeline and a main pipeline comprises a seal installation device capable of moving within the main pipeline to the junction. The seal installation device includes a curable seal for being placed and pressed onto the junction and optionally for extending into the branch pipeline. The assembly further comprises a light curing device for being introduced into the seal installation device within the main pipeline and the branch pipeline for curing the seal.