Robotic Pipe Coating With Vision-Guided Localized Weld Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current in-pipe coating technologies require manual operation and result in redundant coating material usage, as entire circular surfaces are recoated instead of just the defective areas, leading to inefficiencies in labor, cost, and precision.
Innovation Solution
An automated mobile robotic system that includes a first robotic device for detecting and identifying weld joints and anomalies within pipes, and a second device for precise recoating of only the defective areas, utilizing position detection mechanisms and imaging technology for accurate localization and coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used for in-pipe coating, then ease of operation is improved, but productivity deteriorates due to redundant coating of entire circular surfaces
Solution Approach 1:
The robotic system performs autonomous localization of weld joints and anomalies using onboard sensors and imaging devices, then automatically navigates to and coats only the defective areas without continuous human intervention. The system serves itself by detecting, deciding, and executing the coating process autonomously based on real-time inspection data.
2Reliability
If entire circular surfaces are recoated, then reliability of coating coverage is improved, but loss of substance deteriorates due to redundant coating material usage
Solution Approach 1:
The system applies coating material locally only to the specific defective areas (anomalies) detected during inspection, rather than uniformly coating the entire circular weld surface. The robotic nozzle precisely targets and coats only the portions of the weld joint that require repair, minimizing material waste while maintaining adequate coating coverage at defect locations.
3Productivity
If automated robotic system is used for localized recoating, then productivity is improved, but device complexity worsens
Solution Approach 1:
The robotic system integrates multiple functions into a single platform: it performs visual inspection of weld joints, locates anomalies using sensors, navigates to target positions, and executes localized coating operations. This multi-functional design consolidates what would otherwise require separate inspection and coating equipment, managing complexity through integration rather than multiplication of components.
4Ease of operation
If manual positioning is used for coating, then ease of operation is improved, but manufacturing precision deteriorates due to inability to accurately localize anomalies
Solution Approach 1:
The system uses onboard imaging devices and sensors to continuously monitor and detect the robot's position relative to the weld joint and anomalies. This real-time feedback information is processed to automatically adjust the nozzle positioning and coating application, ensuring precise targeting of defective areas without relying on manual operator skill or visual estimation.
Data Source
AI summary
An automated system for performing multiple operations on one or more weld joints of a pipe string includes a main controller including a user interface; and a first robotic device that is in communication with the main controller and is configured to controllably travel inside of the pipe string and detect and uniquely identify each weld joint within the pipe string based on a vision-based weld detection module that is executed on a first onboard computer. The vision-based weld detection module provides at least one of: (1) images captured within the pipe string and (2) a live video feed within the pipe string that is displayed on the user interface for allowing a user to review and approve detection of the weld joint, whereupon once the user confirms the approval, the first robotic device automatically positions itself a predefined distance from the detected weld joint and automatically begins to perform at least one operation on the weld joint.