Digital platform for defect-free plastic pipes welding
Plastic pipes are prone to premature joint failure, both during the installation phase and when in service. This may arise from the welding practices used, resulting in defects such as cracks, cavities, inclusions, deformation and cold joints. Overall, this type of situation can lead to costly and time-consuming disruption of day-to-day operations. Therefore, in order to mitigate the potential for service interference and ensure quality control, contractors have to carry out destructive and non-destructive testing (NDT) on a percentage of operational joints in-situ.
The DIGIPIPEWELD project is addressing these issues with the design, development and delivery of a novel process, for welding joints while simultaneously testing the results against known parameters and avoiding possible failures. Furthermore the autonomous system will utilise disruptive technologies to offer pipe weld manufacturing and self-testing in a right-first-time package; something that has never been done before, and eliminate the risks associated with human error.
The joining of polymer pipes without defects will be achieved by building on the technology of the intelligent, digitally controlled, PinWeld plastic pipe welding system. Incorporation of robotics and sophisticated machine-learning algorithms will enable optimisation and recording of joints, whatever the application and climate, and advanced sensing and data processing will provide accurate monitoring, autonomous quality inspection after welding and real-time leakage detection, bringing a level of control to plastic pipes installation never before available. Research will also explore the potential of digital intelligence to enhance traditional manufacturing processes.
As a brand-new process for joining plastic pipes, the DIGIPIPEWELD system produces a joint that has the same physical properties as the original pipe. This offers installers and operators a higher level of safety, consistency, reliability and speed, resulting in better efficiency and lower energy consumption. Longer term, the system is also expected to contribute to driving down the expenditure required to maintain leak-free water networks.
Partners: Pinweld Ltd, ATS Applied Tech Systems Ltd, Rainbow Engineering Ltd and J4IC.
DIGIPIPEWELD secured an Innovate UK Smart Grant under Grant Agreement no. 1005500.