Plugging Apparatus, System and Method for Pipe Lining Applications

Abstract

A plugging apparatus adapted to plug service lateral openings in the interior of a pipe and a method of plugging service lateral openings, the plugging apparatus having a housing, transport mechanisms mounted to said housing, the transport mechanisms adapted to move the housing through a pipe having service lateral openings, a rotatable manipulator compartment mounted to the housing, the manipulator compartment containing a robotic arm assembly having a plug gripping assembly and an extension assembly; the housing retaining plugs and one or more plug loading actuators adapted to individually advance each of the plugs into the manipulator compartment and the plug gripping assembly, the extension assembly being adapted to extend a plug positioned in the plug gripping assembly radially from the manipulator compartment and into one of the service lateral openings in the pipe.

Claims

1. A plugging apparatus adapted to plug service lateral openings in the interior of a pipe, the plugging apparatus comprising: a housing; transport mechanisms mounted to said housing, said transport mechanisms adapted to move said housing through a pipe having service lateral openings; a rotatable manipulator compartment mounted to said housing, said manipulator compartment containing a robotic arm assembly, said robotic arm assembly comprising a plug gripping assembly and an extension assembly; said housing retaining plugs and one or more plug loading actuators adapted to individually advance each of said plugs into said manipulator compartment and said plug gripping assembly; said extension assembly being adapted to extend each of said plugs positioned in said plug gripping assembly radially from said manipulator compartment and into one of the service lateral openings in the pipe.

2. The apparatus of claim 1, said plug gripping assembly comprising a receiver base, clamp members and a clamp actuator, said clamp actuator adapted to close said clamp members to retain and open said clamp members to release one of said plugs positioned on said receiver base.

3. The apparatus of claim 1, said extension assembly comprising an extension shaft connected to said gripping assembly and an extension actuator adapted to extend and retract said extension shaft.

4. The apparatus of claim 1, said housing further retaining a plurality of chutes, said chutes retaining said plugs in rows, one of said plug loading actuators being associated with each of said chutes; said manipulator compartment comprising a feed opening, wherein said manipulator compartment is rotatable to align said feed opening with one of said chutes such that each of said plugs is advanced through said feed opening into said manipulator compartment and said plug gripping assembly.

5. The apparatus of claim 1, said plugs comprising an insertion portion and a head portion.

6. The apparatus of claim 1, further comprising alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation.

7. The apparatus of claim 2, said extension assembly comprising an extension shaft connected to said gripping assembly and an extension actuator adapted to extend and retract said extension shaft.

8. The apparatus of claim 7, said housing further retaining a plurality of chutes, said chutes retaining said plugs in rows, one of said plug loading actuators being associated with each of said chutes; said manipulator compartment comprising a feed opening, wherein said manipulator compartment is rotatable to align said feed opening with one of said chutes such that each of said plugs is advanced through said feed opening into said manipulator compartment and said plug gripping assembly.

9. The apparatus of claim 8, said plugs comprising an insertion portion and a head portion.

10. The apparatus of claim 9, further comprising alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation.

11. The apparatus of claim 8, further comprising alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation.

12. The apparatus of claim 7, further comprising alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation.

13. The apparatus of claim 6, wherein said alignment control systems comprise cameras.

14. The apparatus of claim 6, wherein said alignment control systems comprise sensors.

15. The apparatus of claim 1, wherein said transport mechanisms comprise extendable and retractable treads, rollers or wheels.

16. The apparatus of claim 1, wherein said plugs are composed of a liquid-soluble material.

17. The apparatus of claim 16, wherein said plugs are provided with a hydrophobic coating.

18. A plugging apparatus adapted to plug service lateral openings in the interior of a pipe, the plugging apparatus comprising a housing; transport mechanisms mounted to said housing, said transport mechanisms adapted to move said housing through a pipe having service lateral openings; a rotatable manipulator compartment mounted to said housing, said manipulator compartment containing a robotic arm assembly, said robotic arm assembly comprising a plug gripping assembly and an extension assembly; said housing retaining plugs and one or more plug loading actuators adapted to individually advance each of said plugs into said manipulator compartment and said plug gripping assembly; said extension assembly being adapted to extend each of said plugs positioned in said plug gripping assembly radially from said manipulator compartment and into one of the service lateral openings in the pipe; said plug gripping assembly comprising a receiver base, clamp members and a clamp actuator, said clamp actuator adapted to close said clamp members to retain and open said clamp members to release one of said plugs positioned on said receiver base; said extension assembly comprising an extension shaft connected to said gripping assembly and an extension actuator adapted to extend and retract said extension shaft; said housing further retaining a plurality of chutes, said chutes retaining said plugs in rows, one of said plug loading actuators being associated with each of said chutes; said manipulator compartment comprising a feed opening, wherein said manipulator compartment is rotatable to align said feed opening with one of said chutes such that each of said plugs is advanced through said feed opening into said manipulator compartment and said plug gripping assembly; said plugs comprising an insertion portion and a head portion, and said plugs composed of a liquid-soluble material and having a hydrophobic coating; said transport systems comprising extendable and retractable treads, rollers or wheels; and further comprising alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation, said alignment control systems comprising cameras or sensors.

19. A method of plugging service lateral openings in a pipe comprising the steps of: providing a plugging apparatus comprising a housing; transport mechanisms mounted to said housing, said transport mechanisms adapted to move said housing through a pipe having service lateral openings; a rotatable manipulator compartment mounted to said housing, said manipulator compartment containing a robotic arm assembly, said robotic arm assembly comprising a plug gripping assembly and an extension assembly; said housing retaining plugs and one or more plug loading actuators adapted to individually advance each of said plugs into said manipulator compartment and said plug gripping assembly; said extension assembly being adapted to extend each of said plugs positioned in said plug gripping assembly radially from said manipulator compartment and into one of the service lateral openings in the pipe; navigating said plugging apparatus said plugging apparatus through a pipe; locating a service lateral opening; aligning said manipulator compartment and said robotic arm assembly with the service lateral opening; extending said robotic arm assembly and inserting one of said plugs into said service lateral opening; and releasing said one of said plugs and retracting said robotic arm assembly.

20. The method of claim 19, wherein said plugging apparatus further comprises alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation; and wherein said steps of navigating, locating, and aligning are controlled by said alignment control systems.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a perspective view of an embodiment of the plugging apparatus, shown in the non-loaded state.

[0015] FIG. 2 is an end view as seen from the longitudinal or transport axis of the plugging apparatus of FIG. 1.

[0016] FIG. 3 is a top view, relative to the orientation shown in FIGS. 1 and 2, of the plugging apparatus of FIG. 1.

[0017] FIG. 4 is a side view, relative to the orientation shown in FIGS. 1 and 2, of the plugging apparatus of FIG. 1.

[0018] FIG. 5 is a cross-sectional view of the plugging apparatus of FIG. 1, taken along line B-B of FIG. 4.

[0019] FIG. 6 is a cross-sectional view of the plugging apparatus of FIG. 1, taken along line A-A of FIG. 4.

[0020] FIG. 7 is an exposed perspective view of an alternative embodiment of the plugging apparatus, shown from the end opposite the manipulator compartment and in the non-loaded state.

[0021] FIG. 8 is an exposed perspective view of the embodiment of the FIG. 7, shown from the manipulator compartment end.

[0022] FIG. 9 is an exposed end view of the embodiment of FIG. 7.

[0023] FIG. 10 is an exposed perspective view of the embodiment of FIG. 7, shown from the manipulator end with a plug in the loaded state.

[0024] FIG. 11 is an exposed perspective view of the embodiment of FIG. 7, shown from the manipulator end with a plug in the extended state.

DETAILED DESCRIPTION OF THE INVENTION

[0025] With reference to the drawings, which are meant to be non-limiting as to the scope of the invention and are not to scale, the invention is shown and described in various embodiments. In a broad sense, the invention is a plugging apparatus, system and method of plugging circular service lateral openings in a pipe prior to its undergoing rehabilitation by a SIPP process or similar process, such that the with the plugs inserted into the service lateral openings, polymer material sprayed to coat the inner wall of the pipe will not block the service openings.

[0026] After cleaning the pipe using conventional methods, such as blasting, pigging, etc. all the service lateral openings need to be covered. To achieve the task a plugging apparatus or robot is sent into the pipe. This apparatus can be semi-autonomous or fully automated. In the semi-autonomous configuration, the apparatus is connected to an umbilical cord which provides it with the required power and wired data communication protocol. In a fully-automated configuration, the plugging apparatus is powered using batteries and uses wireless communication protocol for data transmission. A semi-autonomous system will require an operator to navigate and execute various task of the robot in contrast to the fully-automated system, which may be self-sufficient.

[0027] Alignment control systems 19, such as cameras and sensors, are mounted on the plugging apparatus for navigation, locating service lateral openings, proper positioning of the apparatus relative to the openings, and confirmation of a successful plugging operation. The cameras 19 mounted on the apparatus guide the apparatus through the pipe and transmit HD quality data to the end user so that the operator can have real time images of the pipe. The cameras 19 are preferably surrounded with a ring of LEDs to provide clear images even in dark environment. A secondary camera 19 in addition to the primary navigating camera 19 may be provided on each apparatus to provide concentrated images of the service lateral opening being plugged. Alternatively and preferably, the alignment control devices 19 automatically navigate, locate service lateral openings, properly position the apparatus relative to the openings, and confirm a successful plugging operation.

[0028] Transport mechanisms 11 mounted at spaced locations on the plugging apparatus main housing 10 move and support the apparatus within the pipe. The transport mechanisms 11, which are preferably powered, comprise reads, rollers, wheels or similar members preferably mounted on extendable and retractable assemblies such that the transport mechanisms can be extended or retracted as required for proper fit within the pipe. The transport mechanisms 11 are oriented such that the plugging apparatus moves longitudinally through the pipe.

[0029] A manipulator compartment 12 is rotationally mounted to the main housing 11 with the rotational axis of the manipulator compartment 12 aligned to be coaxial with or parallel to the central longitudinal axis of the pipe as the plugging apparatus moves through the pipe. The rotating manipulator compartment 12 is mounted in a manner allowing it to rotate relative to the non-rotating main housing 10. This may be accomplished in various ways, one of which is illustrated wherein the manipulator compartment 12 is mounted on a shaft 13 extending from a powered rotator actuator 14. Bearings and seals are provided at the junction of the manipulator compartment 12 and main housing 10.

[0030] The main housing 10 acts as a storage compartment for a plurality of cylindrical plug or insert members 90. Each plug 90 is composed of a compressible or resilient material, such as a rubber or polymer, and is configured for ease of insertion in to the circular service lateral openings as well as suitable retention within the opening. For example, in the embodiment shown in the drawings, each plug 90 comprises a head portion 92 and an insertion portion 91, the insertion portion being provided with annular grooves 93 to reduce friction during insertion while creating an effective seal within the service lateral opening. Alternatively, the insertion portion 91 could be tapered or otherwise configured.

[0031] In a preferred embodiment, the plug 90 is made of a liquid-soluble material comprising of a low molecular weight polymer and a surfactant, the material being chosen such that it readily dissolves in water or upon application of heat. The plug head portion 92 may be encapsulated or coated with hydrophobic or similar material which repels or prevents adhesion of the lining material later applied to the pipe, thereby precluding the lining material from encasing or trapping the plug 90 such that it cannot be readily, dissolved, removed or expelled from the service lateral opening once the pipe is put back into service.

[0032] The plugs 90 are stored in longitudinally-oriented rows on or in chutes or rails 16. A plug loading actuator 17 associated with each chute 17, powered by a servo motor or similar means, pushes the row of plugs 90 in the direction of the manipulator compartment 12 as required to load a plug 90 onto the robotic arm assembly 20, the manipulator compartment having a feed opening 15 in its interior-facing wall that allows a plug 90 to be moved into the receiver base 22 of the robotic arm assembly 20 when the feed opening 15 is rotated into alignment with a chute 17.

[0033] The robotic arm assembly 20 is housed within the manipulator compartment 12, and is the mechanism that inserts a plug 90 into a service lateral opening. The robotic arm assembly 20 comprises a plug gripping assembly 21 to retain and release the plug 90 during the insertion operation and an extension assembly 25 to extend and retract the gripping assembly 21 through an insertion window or opening 18 during the insertion operation.

[0034] A first embodiment of the plug gripping assembly 21 is shown in FIGS. 1 through 6 and a second embodiment is shown in FIGS. 7 through 11. In both embodiments the gripping assembly 21 comprises a receiver base 22 adapted to receive the plug 90 when delivered from the main housing 10. The receiver base 22 preferably provides a floor or similar structure that enables pressure to be applied against the plug head portion 92 when the plug 90 is extended radially, relative to the longitudinal axis, into a service lateral opening. The gripping assembly 21 further comprises clamp members 23 controlled by a powered clamp actuator 24, the clamp members 23 being articulated, hinged or otherwise manipulatable so as to be able to be opened or spread laterally to allow a plug 90 to be fed from a chute 17 into the receiver base 22, closed to securely grasp and retain the plug 90 during the insertion operation, and again opened to release the plug 90 once it is inserted into the service lateral opening. The extension assembly 25 extends and retracts the gripping assembly 21 and comprises an extension shaft 26 connected to the gripping assembly, preferably to the receiver base 22, and an extension actuator 27 adapted to extend and retract the extension shaft 26.

[0035] In operation, the plugging apparatus advances or is advanced through the pipe until the alignment control systems 19, sensors and/or cameras, provide signals or visuals that a service lateral opening has been found. Although manual alignment is possible, it is preferred that the plugging apparatus automatically align itself with the service lateral opening in the longitudinal direction relying on information from the alignment devices 19 and that the manipulator compartment 12 automatically rotate about its axis to properly orient the robotic arm assembly 20 with the service lateral opening. If in the non-loaded state, as shown in FIGS. 1 through 9, the manipulator compartment 12 is rotated to align the feed opening 15 with a chute 17 containing a plug 90. The plug loading actuator 17 is then activated, by an operator or preferably automatically, and a plug 90 is advanced into the receiver base 22 of the gripping assembly, as shown in FIG. 10. The clamp members 23, opened to allow passage of the plug 90, are now closed by the clamp actuator, manually or preferably automatically, to securely retain the plug 90 within the receiver base 22. The manipulator compartment is then rotated manually or preferably automatically to align the plug 90 concentrically with the service lateral opening.

[0036] Once properly aligned, the extension actuator is manually or preferably automatically activated to radially advance the plug 90 through the insertion window 18 of the manipulator compartment 12 and toward the service lateral opening, as shown in FIG. 11, the plug 90 being loaded into the receiver base 22 such that the insertion portion 91 extends outward. Activation of the extension actuator 27 radially advances or extends the extension shaft 26 until the insertion portion 91 of the plug 90 is seated in the service lateral opening, the receiver base 22 pushing against the plug head portion 92. Once seated, the clamp members 23 are opened, manually or preferably automatically, by the clamp actuator 24 to release the plug 90, and the extension shaft 26 is retracted, manually or preferably automatically, by the extension actuator 27 to retract the gripping assembly 21 through the insertion window 18 and into the manipulator compartment 12. The plugging apparatus is then advanced to the next service lateral opening and the process is repeated until the supply of plugs 90 has been exhausted.

[0037] It is understood that equivalents and substitutions for certain elements and steps described above may be obvious to those of skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims.