In-Pipe Robotic 3D Printing for Elevated Tubular Wall Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Elevated pipes suffer from wall loss due to excessive differential pressure, leading to operational shutdowns for repairs, which are challenging and costly, especially in hard-to-reach locations.
Innovation Solution
Robotic tools with a printing arm and legs that can move along the pipe's inner surface, depositing a mesh of fibers at different angles and a final polymer layer to repair wall loss without disassembly, enabling in-situ repairs and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manual repair methods are used for elevated pipes, then repair quality can be maintained, but operational shutdown time increases and repair costs increase due to difficulty in access
Solution Approach 1:
The patent replaces manual mechanical repair operations with an automated robotic system that uses 3D printing technology to deposit repair material directly onto the pipe surface. The robotic arm with controlled printing head eliminates the need for manual intervention in hard-to-reach elevated locations, thereby reducing operational shutdown time while maintaining repair quality through precise automated material deposition.
Solution Approach 2:
The patent changes the state of repair material from traditional forms to printable polymer materials that can be extruded and deposited layer by layer. This parameter change in material form enables automated deposition processes, reducing the time required for manual repair operations while ensuring consistent repair quality through controlled material extrusion and layering.
2Ease of manufacture
If manual repair intervention is performed at elevated locations, then repairs can be executed, but safety risks increase and operational disruptions increase
Solution Approach 1:
The robotic system replaces human operators in elevated and potentially hazardous locations, eliminating safety risks associated with manual intervention. The automated system can perform repairs without exposing workers to heights, pressure, or other hazardous conditions while maintaining the capability to execute repairs on elevated pipes.
Solution Approach 2:
The robotic system operates autonomously to perform repair operations, self-navigating to the required positions on the pipe and executing the repair process without continuous human intervention. This self-service capability reduces operational disruptions by enabling repairs to proceed independently once deployed, minimizing the need for ongoing human presence and associated safety risks.
3Adaptability or versatility
If conventional repair methods are used, then existing repair capabilities can be utilized, but repair costs increase and efficiency decreases for hard-to-reach locations
Solution Approach 1:
The robotic 3D printing system is designed with universal applicability to repair various types of pipes in diverse locations, including elevated and hard-to-reach areas. The system can adapt to different pipe geometries and repair scenarios through programmable control, maintaining versatility while dramatically improving repair efficiency through automated operations compared to conventional manual methods.
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 robotic system allows for remote, efficient, and cost-effective pipe repairs at elevated locations, reducing the need for physical intervention and minimizing operational disruptions.
Implementation Method 1
The printing arm can move in x, y, and z-directions. The control system helps the robotic tool to locate the damaged area of the pipe... The methods allow initial patching of the pipe areas (e.g., pipe areas with wall loss). The methods can include depositing a mesh of fibers at two different angle orientations and depositing a final polymer layer (e.g., thermoplastic fiber material) over the same area where the two layers of fiber mesh were deposited at two different angles.
Data Source
AI summary
Robotic tools, methods, and systems for repairing pipes in-situ are described. A robotic tool includes a body with an annular, cylindrical configuration with a first end and a second end opposite the first end, the body having an inner surface defining an axis; a printing arm attached to the inner surface of the robotic body using a track, the printing arm circumferentially movable along the inner surface of the body; a printing head attached to the printing arm, the printing head movable radially along the printing arm and axially relative to the printing arm; and a plurality of legs positioned at axial intervals around the robotic body, each leg pivotably attached to the robotic body at either the first end or the second end of the body and pivotable between an open position and a closed position.