Rack-Type Pipe Feeder for Fusion Machines
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Solution Overview
Problem
The handling and staging of high-density polyethylene (HDPE) pipes for fusion machines are labor-intensive and time-consuming, requiring expensive equipment and causing significant downtime, as existing solutions are inadequate for efficiently loading and aligning large diameter pipes due to the need for manual adjustment and heavy lifting equipment.
Innovation Solution
A modular pipe feeder system with adjustable racks, V-shaped cam dispensers, and powered stands that use gravitational force and hydraulic systems to align and load pipes of varying diameters into fusion machines, allowing for automated alignment and loading of multiple pipes simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heavy lifting equipment (fork trucks, cranes) is used to handle large diameter pipe sticks, then the pipe loading capability is improved, but the operation time increases and requires multiple operators
Solution Approach 1:
The pipe storage rack is pre-positioned at the fusion machine location with multiple pipe sticks stored on it. The V-shaped cam is pre-configured in the dispenser mechanism. When needed, the cam simply rocks to release the next pipe stick without requiring heavy equipment to transport pipes from distant locations, dramatically reducing operation time.
Solution Approach 2:
The V-shaped cam acts as an intermediary mechanism between the stored pipes and the fusion machine. It automatically controls the release and positioning of pipe sticks through its rocking motion, eliminating the need for manual handling by multiple operators and reducing operation time while maintaining ease of loading.
2Ease of operation
If heavy lifting equipment is used to load pipe sticks, then large diameter pipes can be handled, but expensive equipment and multiple operators are required
Solution Approach 1:
The pipe storage rack system is designed to be self-sufficient. Pipes are loaded onto the rack once using standard equipment, then the V-shaped cam dispenser automatically releases and positions subsequent pipe sticks without requiring heavy lifting equipment or multiple operators. The system serves itself by maintaining a local supply of pipes and automatically dispensing them as needed.
Solution Approach 2:
Multiple pipe sticks are pre-loaded onto the storage rack before the fusion operation begins. This preliminary action eliminates the need for repeated heavy equipment intervention during the fusion process, reducing both equipment complexity and operational costs while maintaining the ability to handle large diameter pipes.
3Device complexity
If manual alignment methods are used for pipe sticks, then equipment cost is reduced, but alignment precision deteriorates
Solution Approach 1:
The V-shaped cam serves as a precision intermediary device that mechanically controls the release and positioning of pipe sticks. Its fixed geometric shape and controlled rocking motion ensure that each pipe stick is released at the correct position and orientation, providing precise alignment without requiring complex adjustment equipment or manual intervention.
Solution Approach 2:
The V-shaped cam is pre-configured with the correct geometry and positioning for the specific pipe diameter and fusion machine requirements. This preliminary setup ensures that subsequent pipe releases are automatically aligned with the required precision, eliminating the need for manual alignment adjustments while maintaining high accuracy.
4Device complexity
If pipe sticks are stored on the ground, then equipment complexity is reduced, but downtime increases due to repeated lifting
Solution Approach 1:
Multiple pipe sticks are pre-loaded onto the storage rack and positioned in the immediate vicinity of the fusion machine before the fusion operation begins. This preliminary preparation creates a local supply buffer, allowing the fusion machine to continue operating without interruption while pipe sticks are automatically dispensed from the rack, dramatically reducing downtime despite the added storage equipment.
Solution Approach 2:
The storage rack with V-shaped cam dispenser acts as an intermediary buffer between the distant pipe supply and the fusion machine. It maintains a ready supply of pipe sticks locally, allowing automatic dispensing without requiring the fusion machine to stop for repeated heavy lifting operations, thereby improving productivity while accepting moderate equipment 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 system reduces the need for heavy lifting equipment and manual alignment, enabling efficient and automated loading of pipes of different diameters, minimizing downtime and labor requirements while ensuring precise alignment with the fusion machine.
Implementation Method 1
The rack is inclined so as to cause stored sticks of pipe to roll toward and onto a transfer path
Data Source
Figure 1~2
Figure 3~4
Figure 5A~6
AI summary
For use in loading heavy sticks of plastic pipe (P) into a pipe fusion machine, a pipe storage rack (10; 310) with hydraulically powered pipe stick dispensers (330) and stands (360, 390) allows sticks of pipe (P) stored on the rack (10; 310) to roll gravitationally onto a rocking V-shaped dispenser cam (331) disposed between the rack (10; 310) and the fusion machine loading path (T) for one-stick-at-a-time loading onto powered track and roller stands (360, 390) which enable Cartesian manipulation of the stick (P) into the fusion machine. The cam (331) is adjustable to suit pipe stick (P) diameters ranging from 20" (50.8 cm) to 48" (121.92 cm). Many sticks can be stored at one time, releasing heavy lifting equipment and operators to work elsewhere. The process requires only one operator using a pendant controller and the pipe sticks (P) are handled by heavy equipment only when being loaded onto the racks (10; 310).