Modular Rack Pipe Feeder for Fusion Machines
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Solution Overview
Problem
Current methods for feeding sticks of pipe into a pipe fusion machine are labor-intensive and require expensive equipment, leading to significant downtime due to the need for handling each pipe individually, and existing solutions are not effective for multiple pipes or varying terrain and machine sizes.
Innovation Solution
A modular rack-type pipe feeder system with adjustable beams and rollers that supports multiple pipes, allowing for efficient alignment and feeding into a pipe fusion machine, eliminating the need for heavy equipment to handle individual pipes and accommodating different terrain and machine sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heavy equipment (telehandlers, backhoe loaders, fork trucks) is used to handle each stick of pipe individually, then pipe handling capability is provided, but labor costs and equipment costs increase significantly
Solution Approach 1:
The system segments the pipe handling function by providing multiple independent feeders (typically three) that can be positioned at different locations. Each feeder handles a bundle of pipes independently, eliminating the need for single-unit heavy equipment to move each pipe individually. This segmentation distributes the handling workload across multiple simpler, smaller units.
Solution Approach 2:
The feeders are designed to be self-positioning on the terrain using adjustable legs with jacks, and the pipes are fed automatically from the bundles through gravity-assisted rolling mechanisms. This reduces the need for continuous heavy equipment intervention, allowing the system to serve itself in terms of positioning and pipe delivery.
2Ease of operation
If heavy equipment is used for each individual pipe handling, then pipe feeding is achieved, but downtime of the fusion machine increases
Solution Approach 1:
Pipes are pre-bundled and staged on the feeders before the fusion machine needs them. The feeders maintain ready supplies of pipes in bundles, so when the fusion machine completes a fusion operation, pipes are already prepared and positioned for immediate loading. This preliminary staging eliminates waiting time and keeps the fusion machine continuously operational.
Solution Approach 2:
The system maintains continuous pipe availability through multiple feeders that can be refilled independently. While one feeder is being used, others can be replenished, ensuring that the fusion machine never experiences downtime due to pipe availability. The modular design allows continuous operation without interruption.
3Device complexity
If pipe stands hold only one stick of pipe at a time, then simple structure is maintained, but effectiveness for manipulating multiple pipes decreases
Solution Approach 1:
The system merges multiple simple feeder units into a coordinated system. Each individual feeder maintains structural simplicity like a single-stick stand, but by combining three or more such feeders positioned around the fusion machine, the system achieves the ability to handle multiple pipes simultaneously, dramatically improving productivity while keeping individual components simple.
4Ease of operation
If fixed pipe storage rack combined with single pipe stand is used, then loading ease is improved, but adaptability to varying terrain and machine sizes is reduced
Solution Approach 1:
The feeders incorporate adjustable legs with jacks that allow dynamic height adjustment to accommodate varying terrain contours. The entire feeder assembly can be positioned and leveled on uneven ground. Additionally, the feeders can be moved and repositioned around the fusion machine to adapt to different machine sizes and configurations, providing both ease of operation and high adaptability.
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 system significantly reduces labor and equipment costs by enabling smooth, efficient feeding of multiple pipes into the fusion machine, minimizing downtime and accommodating various pipe sizes and terrain conditions.
Implementation Method 1
A jack is used to vary the height of one of the legs so as to set a beam slope at which the transverse sticks of pipe tend to roll toward the lower front end of the beam
Data Source
AI summary
A rack feeds sticks of pipe to a machine for serial fusion to the trailing end of a pipeline. Multiple independent spaced apart feeders support transverse bundles of sticks of pipe on beams. Legs which support the beams above the ground have jacks to vary the height and slope of the beams. The slope is set so that sticks tend to roll toward the lower front end of the beam where roller assemblies receive the sticks of pipe as they are manually rolled, one at a time, off the beams. All of the rack components are modular and interchangeably connectable so that the feeder can be quickly adapted for a variety of conditions and applications.