Automated RTR Pipe Joint Welding With Internal Pig Alignment
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Solution Overview
Problem
Conventional methods for installing reinforced thermosetting resin (RTR) pipes are prone to human error and have a high failure rate due to the complexity of joint preparation and alignment, especially in high-pressure applications, leading to frequent joint failures and reduced confidence in the material's performance.
Innovation Solution
An automated installation system that combines an induction welding system with a hydraulic/pneumatic caterpillar-like device, which minimizes human interaction by using pneumatic wheels and hydraulic arms for precise alignment and thermoplastic welding of RTR pipe joints, reducing the risk of failure and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual methods are used for installing RTR pipe joints, then installation flexibility and adaptability are maintained, but human error increases and joint reliability decreases due to complexity of preparation and alignment
Solution Approach 1:
The patent replaces manual mechanical alignment and welding operations with an automated system that uses induction heating for welding and a caterpillar-like device with hydraulic arms for precise positioning. This substitution eliminates human error in joint preparation and alignment while maintaining installation flexibility.
Solution Approach 2:
The automated installation system performs its own alignment and welding operations without requiring skilled operators. The system self-adjusts to accommodate field conditions through its flexible caterpillar design and hydraulic positioning mechanisms, making the installation process independent of human expertise.
2Reliability
If automated induction welding system is used, then joint failure rate decreases and reliability increases, but device complexity and initial cost increase
Solution Approach 1:
The patent replaces complex manual alignment and welding procedures with an integrated automated system combining induction heating coils, hydraulic positioning arms, and computer-controlled coordination. This consolidation of functions into a single system reduces operational complexity despite increased device complexity.
Solution Approach 2:
The caterpillar-like installation device serves multiple functions: it positions pipes for alignment, holds joints during welding, and can adapt to various field conditions. This multi-functionality reduces the need for separate equipment for each installation step, managing overall system complexity.
3Manufacturing precision
If manual alignment and positioning methods are used, then equipment cost is lower, but positioning precision and alignment accuracy decrease leading to higher joint failure rates
Solution Approach 1:
The patent replaces manual visual alignment methods with an automated system using hydraulic arms and computer-controlled positioning. The system achieves precise alignment through mechanical feedback and coordinated movement of the caterpillar device, eliminating the imprecision of manual methods.
Solution Approach 2:
The caterpillar-like device uses hydraulic arms and pneumatic cylinders to achieve precise positioning and alignment of pipe joints. These fluid power systems provide controlled, repeatable positioning accuracy that far exceeds manual capabilities while integrating smoothly with the overall automated installation process.
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 automated system significantly reduces joint failure rates, enhances the reliability of RTR pipe connections, and increases productivity by ensuring accurate positioning and sealing of thermoplastic welded joints, even in challenging environmental conditions.
Implementation Method 1
an inductor disposed around the socket end, upon application of induction heating from induction coils of the inductor
Implementation Method 2
the heat between the first pipe and the second pipe is sufficient to melt the thermoplastic material
Implementation Method 3
a pig having a frame disposed in the first pipe and the second pipe. The pig may include a piston with a first telescopic arm extending axially outward from one end of the piston and a second telescopic arm extending axially outward from an opposite end of the piston; a first pneumatic wheel on the first telescopic arm
Data Source
AI summary
A system and method for automatically jointing of reinforced thermosetting resin (RTR) pipes. For example, an automated installation of RTR joints system may have an inductor and a pig for automated in-field installation of RTR pipes. The inductor may be fitted on an outside of RTR joint. Additionally, the pig may be inserted inside the pipeline and remotely controlled to assist operators during the alignment of the pipes and subsequent joint making/welding. Through the successive inflation and deflation of pneumatic wheels placed along the pig, the pig may autonomously move inside the RTR pipeline (from one RTR joint to the other) during the installation, while also be used to apply internal pressure at specific locations of the pipe, as needed, during installation.