Not applicable.
Not applicable.
The present invention relates generally to the field of cleaning apparatus for large diameter pipes and more particularly to such an apparatus which uses a basic structure for cleaning pipes with spray arms and circulating high pressure nozzles, but which is expandable for use in a wide range of diameters of pipes. The present invention further relies on an automatic synchronization of the travel of the nozzles in tangential and advancing directions.
In various applications the insides of large pipelines have deposits or damaged protective liners which have to be removed periodically. Cleaning jets exiting rotating nozzles should remove deposits from the pipeline wall and flush debris away. Therefore, it is beneficial for the traces of the cleaning jets to overlap in order to generate a homogeneously clean surface.
European Patent No. EP 2 139 621 B1 discloses a self-propelled cleaning apparatus with opposite driving wheels and with opposite guiding wheels, which are expandable for a limited range of pipe diameter. The expansion of the wheels to fit different diameter pipes is limited by the length of movable parallel supporting arms and by the stroke of attached cylinders, which are individual to each wheel. In the frontal region of the apparatus a high-pressure water feeding hose feeds into a high pressure coupling to a rotating hollow shaft with two spray arms and thereon attached spay nozzles. Rotation is achieved by an air motor, which with a driving belt drives simultaneously the hollow shaft and one of the driving wheels via a chain of cardan shafts. Further driving wheels have individual air motors, which drive the wheel via a worm gear for developing higher and more equally distributed pulling forces. So, there are two different air driven systems, which must care for a simultaneous advance movement at opposed driving wheels. The ratio between circumferential speed of the nozzles and advance movement should be kept constant for improved cleaning results. When the system is enlarged to a larger pipe diameter, the nozzles with elongated nozzle arms would cut at a higher circumferential speed and therefore the rotational speed and the advance speed of all air driven wheels should be lowered. Furthermore, some driving wheels run at the deepest bottom of the pipe, where the cut away debris is assembling. It would therefore be advantageous to develop a cleaning apparatus that is adjustable to different size pipes and maintains proper speed at the wheels and cleaning nozzle.
It is the aim of the invention to create an effective pipe cleaning apparatus for large pipe diameters and long pipes, which apparatus is functional safe, whereby a basic apparatus can be easily modified for larger pipe diameters.
With the choice of one main single air motor attached to a worm gear, which drives a central hollow shaft with one driving sprocket and with the choice of equal driving sprockets on the hollow shaft driving with equal roller chains identical off-the shelf worm gears, which drive with equal sprocket gears identical driving wheels, a simultaneous advance movement is mechanically achieved. And with a pressure wheel situated between the forward and the rear driving wheels on the top of the apparatus, enough pressure is achieved at the driving wheels to prevent their slipping.
With the reduced speed in the kinematic chain to the driving wheels the transferred torque moments and bearing forces increase. This fact is covered by the know how in the off-the-shelf worm gears and by a heavy structure of the driving wheels frames. Therefore, in the last transmission from the worm gear to the driving wheel the output sprocket of the worm gear has a small diameter, whereas the diameter of the driving wheel sprocket is close to the diameter of the driving wheel.
The worm gears attached on the left side of the angles are identical with the worm gears at the right side of the angles. When left side worm gears would be turned by 180 degrees for fixation at the right side, the attached driving wheels would drive in the opposite direction. But seen from this side the hollow shaft turns in opposite direction and turns the driving wheel in the same direction as on the left side. With this arrangement the structure becomes compact, there is space for the roller chains and all worm gears for the driving wheels are identical. Thus, the mechanically synchronized drives result in a constant and precise cleaning track and regardless of power supply fluctuations the cleaning track geometry will not be influenced. Operators will only have to adjust the speed of the single drive motor for adapting the jet cleaning abilities to the type of debris/pipe-coating that needs to be removed.
The off-the-shelf worm gear boxes for all wheel drives are identical in housing dimensions and extended shaft ends. They are available with various gear ratios allowing pitch changes of the spiral shaped cleaning track by simply swapping the worm gear boxes. Using driving wheels with a diameter of 10″, a chain drive transmission ratio of 1:2 between the wheels and the output shafts of the wheel-drive worm gear boxes, a transmission ratio of 1:30 between the output shaft and input shaft of the wheel-drive worm gear boxes, a chain drive transmission ratio of 1 between the input shafts of the wheel-drive worm gear boxes and the hollow drive shaft, the resulting pitch of the spiral, that the cleaning jet track of a single cleaning nozzle moved by the rotor head would generate on the pipe wall, would be slightly larger than 0.5″ (0.524″). Fitting the rotor head with two opposing cleaning nozzles would result in cleaning jet tracks with 0.25″ between two adjacent tracks. The rotational speed of the hollow drive shaft and thus for the rotor head would be adjusted for a suitable cleaning jet travel velocity across the pipe surface for obtaining best cleaning results.
By maintaining the wheel diameter and these transmission ratios, the same spiral pitch will result on the pipe wall regardless of pipe diameter.
It is another advantage that all worm gears driving the driving wheels are equal in output speed, when the transmissions from the sprocket gears of the hollow shaft to input sprockets gears of the worm gears are the same with the same distance of the shafts. For enlarged applications with spacer elements it makes it easy to install between the hollow shaft and the worm gears a further shaft with a 1:1 transmission and maintaining the main components without changing the speed of the driving wheels. As the speed reduction is stepwise to lower speeds there are no problems with critical speeds for the involved shafts.
It is a further advantage for the stability of the apparatus when the pressure wheel on the top gets an additional worm gear for acting as a driving wheel. Nevertheless, for the stability of highly, by spacer elements, enlarged applications with a growing distance of the pressure wheel to the constant distance between forward and rear driving wheels, the drag of supply hoses and smaller obstacles might move the frontal part of the apparatus upwards, the frontal driving wheels might loosen contact to the pipe wall, and the rear driving wheels might be still in action. Therefore, for limiting the inclination a further anti-tilt guiding wheel is installed at a small distance to the pipe wall on the top of the forward casing.
In some parts the hollow shaft comprises two concentric shafts, an inside tube for the transport of pressurized liquid and an outer driving shaft, where the shaft pieces are assembled with bearings and driving sprockets. As the forward and the rear angles consist of bolted on metal sheets, those sheets taking the bearings can be assembled with the bearings and with the driving sprockets by slipping these sidewards in the right followed by the penetrating outer shaft on a mounting frame and fixing them with clamping rings and keys. Later the inside tube prevents leakage of the pressurized liquid.
As mentioned above the constant speed ratio of all driving wheels to the hollow shaft, which rotates the feeding tubes and spray nozzles, allows it to produce the same cleaning trace for the nozzles at all pipe diameters. In order to achieve the required tangential speed of the rotating nozzles, which brings desired cleaning results, the speed of the single air motor must be adapted for each pipe diameter. Therefore, the supply of compressed air consists of two hoses for controlling the speed of the hollow shaft from the entrance of the pipe. The hoses also deliver compressed air to a buffer tank on the apparatus, which is connected to two cylinders spreading the pressure wheel.
Cleaning results are improved by maintaining a constant distance between cleaning jet exit at the spray nozzle and the pipe wall. The spray nozzle assembly of each rotor arm can comprise the spray nozzle with its high-pressure fluid flow connector installed on the same articulating spring-loaded lever as the guide wheel. Since the guide wheel is continuously pressed against the pipe wall by the spring-loaded lever, the spray nozzle will be moved across the wall at constant distance. The spring-loaded lever is either directly connected to a spring and the force between the guide wheel and pipe wall corresponds to the spring force multiplied by the lever ratio of the distance between the hinge point of the arm and the spring attachment point and the distance between the hinge attachment point and the wheel-to-wall contact point. Or alternatively a parallelogram linkage is fitted between the spring attachment point and the spray lever assembly. The spray lever assembly is attached to the rotor arm, which is solidly coupled to the rotor head. The above rotor arm structure would also fit to other cleaning apparatus like the one cited in European Patent No. EP 2 139 621 B1.
So that the manner in which the above recited features, advantages and objects of the present invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
For the basic cleaning apparatus 1 in
A hollow basic drive shaft 61 penetrates the two center angles 2 at bearing flanges 6 (see
The forward and rear center angles 2 shown in
More details can be seen in
In
The hose pull solid 39 in
When the swing arm 25 with the rubber wheel 27 has been installed, the two spreading cylinders 75 are introduced between the cylinder hold with pivot 80 and a clamping bracket 108 (see
The rotor head 99, as shown with details in
The distribution of the sprockets on the drive shaft 61 is shown in
In
The expanded apparatus in
In the pneumatic diagram of
A first embodiment for individually guided nozzles 162 maintaining a constant distance 163 to the pipe wall 170 at a pipe diameter 149 is shown in
The guiding wheel 160 comprises metal with a rounded running surface to reduce wear. Any deviation of the guiding wheel occurs in radial direction in a first radial plane 156. The spray nozzle 162 supported by a connector 164 is attached close to the guiding wheel 160 and follows the radial displacement of the guiding wheel for maintaining a constant distance 163 to the pipe wall 170.
The liquid flow is guided in a second radial plane 157 parallel to the first radial plane 156 at a distance large enough for to have a bore to a blind hole 151 of the connecting flange and for a welded-on support 152. A seal 169 is embedded in the flange 155 and compressed by the connecting flange. The two connectors 152 and 164 are connected by a high-pressure hose 167, a diverting tube piece 165 and a second high-pressure hose 166. The diverting tube piece turns the current by an angle γ 168, whereby it is only held by the high-pressure hoses in the second radial plane 157. High-pressure hoses have an extreme torsional stiffness, and the bending radii are limited. Therefore, the hoses are kept rather long to obtain suitable bending radii and for the diverting tube piece 168 equalizing low bending moments at both sides.
A second embodiment for an extended application of the apparatus is shown in
The moving arm piece 187 is inclined and is holding a guiding wheel 190 with a bearing 191. It also holds a connector and nozzle support 183. The nozzle 185 is situated close to the guiding wheel 190 for maintaining a constant distance 184 to the pipe wall 170, which may have a larger diameter 149 than shown on the drawing. Equally to
This arrangement gives the possibility to adapt the nozzles to any larger pipe diameter by exchanging the extension shaft piece 173 and the high-pressure hose 192. Due to the stiffness of the high-pressure hose 192 the latter is secured first between the connectors 179, 186 and afterwards the extension shaft 173 is definitely fixed by screws and slot holes 174 to the interior and exterior arm pieces 171, 172.
The apparatus 1 can be used in pipeline maintenance operations. For example, the apparatus can be used to remove a coal-tar coating from a 36″ pipeline. The begin the pipeline maintenance, the apparatus 1 can be launched fully assembled into the pipeline. Launching can be accomplished through port openings by excavating the area around the pipeline, then cutting and lifting out a spool piece of the pipeline.
For inserting the apparatus 1 into the pipeline, hoist rings on the apparatus 1 can be used for directly moving the apparatus 1 into the pipeline or, alternatively, a launching jig can be employed to facilitate the insertion (see
A high-pressure water pump with a wastewater recycling system is positioned at the pipe entry point and an air compressor in the same vicinity is connected via supply hoses to the rear end of the apparatus 1. As the apparatus 1 begins the coal-tar coating removal process, the supply hoses are pulled into the pipeline. A feed system for the high-pressure water supply hoses is adjusted to unspool the water supply hose at a rate matching the travel speed of the apparatus 1. Compressed air hoses are similarly pulled into the pipeline at the required rate.
Upon completion of one pipeline section, the apparatus 1 is typically extracted from the full port opening at the end of this pipeline section and transferred into a full port opening of the next pipeline section. Supply hoses are pulled back to the initial starting point and together with the whole supply equipment (water supply circuit and air compressor) moved to the new entry point before being reconnected to the apparatus.
When used in this specification and claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps, or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.
The invention may also broadly consist in the parts, elements, steps, examples and/or features referred to or indicated in the specification individually or collectively in any and all combinations of two or more said parts, elements, steps, examples and/or features. In particular, one or more features in any of the embodiments described herein may be combined with one or more features from any other embodiment(s) described herein.
Protection may be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure. Although certain example embodiments of the invention have been described, the scope of the appended claims is not intended to be limited solely to these embodiments. The claims are to be construed literally, purposively, and/or to encompass equivalents.