Winch Boom and Protected Pulley for Small-Pit Pipe Bursting
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Solution Overview
Problem
Trenchless pipe replacement methods face challenges in minimizing the size of entry and exit pits for operating equipment, particularly when dealing with small spaces and long, large-diameter pipes like HDPE gas pipes, where existing technologies struggle to efficiently manage the operation of cutting tools and bursting tools.
Innovation Solution
A pipe replacement system featuring a boom with adjustable length and pivoting capabilities, including a polymeric bursting tool guide surface on pulleys to protect tools and reduce damage, and a limiter to prevent pipe jamming, allowing for angled deployment and reduced pit size requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional trenchless pipe replacement equipment is used in small entry and exit pits, then pipe replacement can be performed, but the available space for operating cutting tools and bursting tools is severely limited
Solution Approach 1:
The patent introduces a boom structure that extends the operational space from the confined two-dimensional pit area into the third dimension (vertical space above the pit). The boom allows cutting tools and bursting tools to be positioned and operated from above the pit rather than within it, effectively transforming the limited horizontal workspace into a three-dimensional workspace that includes vertical clearance.
Solution Approach 2:
The boom acts as an intermediary mechanical arm between the winch system and the cutting/bursting tools. It transmits force and motion while providing the necessary reach and positioning capability, allowing tools to operate in spaces that would otherwise be inaccessible from the small pit configuration.
2Productivity
If longer bursting tools like reciprocating hammers are used to handle large-diameter pipes, then tool effectiveness is improved, but the risk of pipe jamming and tool damage increases
Solution Approach 1:
The polymeric bursting tool guide surface on the pulley acts as an intermediary protective layer between the bursting tool and the pipe. This polymeric surface reduces friction and prevents direct metal-to-metal or tool-to-pipe contact that could cause jamming or damage, allowing longer tools to operate more reliably.
Solution Approach 2:
The polymeric guide surface provides beforehand cushioning by creating a compliant interface that absorbs shocks and reduces impact forces during tool insertion and operation. This prevents sudden jamming events and protects both the tool and pipe from damage before problems occur.
3Length of moving object
If the boom is made longer to increase operational reach in the pit, then tool deployment capability is improved, but the boom becomes more susceptible to damage from pipe contact
Solution Approach 1:
The boom is constructed from aluminum alloy, which provides a composite-like combination of strength-to-weight ratio. This material choice allows the boom to be sufficiently long for operational reach while maintaining the structural strength needed to resist damage from potential pipe contact and operational loads.
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
Enables efficient trenchless pipe replacement with reduced pit sizes, minimizing road repair and allowing for the use of longer tools like reciprocating hammers without extraction cages, while protecting equipment and maintaining operational space for fittings and tool manipulation.
Implementation Method 1
The cable passes over a pulley having a polymeric bursting tool guide surface
Data Source
AI summary
A pipe replacement system and method are shown. Configurations are shown that include a pulley that does not damage a bursting tool, as the bursting tool is pulled into a pit. Configurations are also shown that include a boom that does not need an extraction cage for the bursting tool.