WO2014182482A1

WO2014182482A1 - Apparatus for spraying reinforcing material onto an interior surface of a pipe

Info

Publication number: WO2014182482A1
Application number: PCT/US2014/035605
Authority: WO
Inventors: Allan Ray JEDNEAK
Original assignee: Inland Pipe Rehabilitation, Llp
Priority date: 2013-05-06
Filing date: 2014-04-28
Publication date: 2014-11-13

Abstract

A sled assembly includes a sled that carries a reciprocating spinner assembly for spraying reinforcing material against the interior surface of a pipe. The reciprocating spinner assembly includes an axial worm gear operatively connected to a reversible drive motor. A dust cover and shroud are arranged to keep the worm gear free of dust and debris. The sled includes skis that have a structural core member and an outer wear member and adjustable frame members by which the height of the reciprocating spinner assembly may be adjusted to be at the center of different diameter pipes. Temperature sensors and an air pressure sensor are arranged to sense the temperature of the spinner and the reinforcing material the pressure of compressed air for the spinner. Lights are arranged to illuminate the working area and to provide a visual indication of which direction the spinner is moving along the worm gear.

Description

APPARATUS FOR SPRAYING REINFORCING MATERIAL ONTO AN INTERIOR SURFACE OF A PIPE

FIELD OF THE INVENTION

[0001] The present disclosure relates generally to an apparatus for spraying reinforcing material onto an interior surface of a pipe, such as for coating, rehabilitation, and/or reinforcement of the pipe, and more particularly, to one or more improvements to a sled assembly that carries a spinner for spraying the reinforcing material against the interior surface of the pipe and/or related delivery, control, and/or monitoring mechanisms on the sled assembly.

REFERENCE TO RELATED APPLICATIONS

[0002] The technology to which the present application relates improves upon technology disclosed in co-pending U.S. Patent Application No. 13/367,315, filed February 6, 2012, the entirety of which is incorporated by reference herein.

BACKGROUND

[0003] Typically, it is preferred that a pipe or other elongate conduit does not leak or allow the product being carried within it to leak outside of the pipe between opposite ends of the pipe. As used herein, the term "pipe" refers generally to any elongate conduit, including, for example, pipes, culverts, tunnels, ducts, hoses, and similar structures. However, many factors can cause pipes to develop leaks, such as cracks, holes, and/or other structural deficiencies in the pipe wall. When this occurs, it is typically necessary to either replace or repair the pipe so as to stop the leakage of the material.

[0004] Many pipes are located in positions that are difficult to access, thereby making it difficult and/or expensive to replace the pipe when such structural deficiencies are identified. For example, sewer pipes, drain pipes, and culverts are frequently disposed underground and can require costly excavation processes in order to be replaced or even serviced. Other pipes may be disposed in very crowded environments, such as congested urban settings or industrial settings, that can similarly require significant effort, inconvenience, disruption, and/or cost to access and repair or replace a leaky pipe. Therefore, it can sometimes be preferable to repair a pipe in situ, i.e., without having to replace and/or remove it from its operative location. Such repairs of relatively large diameter pipe may be performed from the interior of the pipe.

[0005] One known system for repairing and/or reinforcing a pipe from the interior includes using a spraying mechanism to spray sprayable reinforcing material, such as concrete, cement, tar, fiberglass, adhesive, and/or similar materials, against the interior surface of the pipe. One known system includes a so called spinner disposed on a sled, which is drawn along the interior axis of the pipe as the spinner sprays flowable reinforcing material against the inner surface of the pipe wall. The spinner has a rotating spray head that is connected to a source of wet and/or dry cementitious material and/or other types of sprayable reinforcing material and to a supply of compressed air. The compressed air forces the cementitious material at high velocity through the spinner head, which material is then ejected generally radially outwardly from the spinner head along a non-radial flow path, the compressed air causing the spinner head to rotate about an axis aligned with the axis of the pipe, thereby radially spraying or depositing one or more layers of cement around the entire interior surface of the pipe. The sled is moved along the axis of the pipe, such as by being pulled with a cable or chain, as described in more detail in co-pending U.S. Patent Application No. 61/636,386, filed April 20, 2012 and U.S. Patent Application No. 13/737,478, filed January 9, 20123, each of which is incorporated herein by reference. The rotating spray head applies the cement to the inner surface of the pipe as the sled is moved along the axis of the pipe and thereby can cover the interior surface of a substantial length of pipe with cement. In this manner, a pipe, such as a concrete pipe or a corrugated metal pipe, of various dimensions and/or shapes may be completely rehabilitated with an inner lining of cement and/or concrete and/or other similar structural and/or ceiling and/or reinforcing materials in situ without having to remove the pipe from its location.

[0006] It is also known in some arrangements to provide a sled assembly wherein the spinner is disposed on an oscillating platform carried by the sled. In this arrangement, as the sled is pulled in one direction along the axis of the pipe, the spinner oscillating back and forth on the sled and aligned with the center of the pipe. This oscillating motion of the spinner is used to produce a feathered and/or more even application thickness of the cement onto the interior surface of the type in order to minimize the occurrence of excessive thin spots or thick spots of the subsequent lining formed by the cement applied to the interior surface of the pipe. This oscillation has previously been accomplished by a wheel and linkage mechanism that imparts axial motion of plate to which the spinner is secured.

SUMMARY

[0007] According to some aspects of the present disclosure, a reciprocating spinner assembly for spraying reinforcing material against the inner surface of a pipe includes a linear actuator in the form of an axial worm gear operatively connected to a reversible drive motor, a carriage operatively connected to the axial worm gear, and a spinner carried by the carriage. The reversible drive motor rotates the axial worm gear in alternating directions, which reciprocates the carriage and the spinner in a first direction and a second direction along a path of travel disposed axially along the axial worm gear. Preferably, the reversible drive motor is a servo motor and is operatively coupled to a DC controller. The worm gear may be rotatably carried by a bracket, such as with a first end of the worm gear journaled to first thrust bearing and a second end of the worm gear journaled to second thrust bearing. The bracket may include a bottom wall, a first end wall adjacent the first end of the worm gear, and a second end wall adjacent the second end of the worm gear. The thrust bearings may be secured to the bottom wall and/or either or both of the end walls. One or more proximity switches may be disposed along the path of travel of the carriage, such as at either or both opposite ends of the path of travel and/or at opposite ends of the worm gear. The proximity switches may be arranged to cause the reversible drive motor to reverse direction and thereby cause the carriage and the spinner to reverse direction at opposite ends of the path of travel.

[0008] According to some aspects of the present disclosure, a sled for carrying the reciprocating spinner assembly includes at least one, and preferably two or more, skis for slidably supporting the sled assembly on the interior surface of a pipe, such as a corrugated pipe. One or more of the skis may include an axially elongate structural core member, such as a metal tube, and an outer wear cover, such as a polymer channel, disposed along a bottom surface of the elongate structural member. The polymer channel may be secured to the outer surface of the structural core member with fasteners, such as screws, bolts, or clips. The exposed bottom of the wear cover also may serve as a friction-reducing bearing surface between the skis and the interior wall of the pipe.

[0009] According to some aspects of the present disclosure, the sled has a frame that can be readily and selectively adjusted to maintain the spinner generally radially centered within pipes of different sizes. In some arrangements, the sled includes one or more triangular frames with adjustable frame members that can be selectively lengthened and/or shorted in a vertical and/or horizontal direction to move a support platform for the reciprocating spinner assembly upwardly and/or downwardly. The adjustable frame members may be locked into a selected length with locks, such as standard scaffold clips.

[0010] According to some aspects of the present disclosure, the linear actuator of the reciprocating spinner assembly includes a flexible shield, such as an accordion style dust cover, covering the worm gear to minimize exposure of the worm gear to debris. The shield extends to opposite first and second ends of the worm gear and may have an axial channel shape, such as an upside down U-shaped cross section, with a top wall and two downwardly depending sidewalls along opposite transverse sides of the top wall. Preferably, the shield includes first and second sections disposed on opposite sides of the carriage. The first section may have a first end connected to a first side of the carriage and a second end connected to the first end wall of the bracket disposed at the first end of the worm gear. The second section may have a first end connected to a second side of the carriage and a second end connected to the second end wall of the bracket disposed at the second end of the worm gear. Preferably, the first and/or second sections of the shield are formed of a flexible material, such as plastic or cloth, in an accordion arrangement, i.e., with a plurality of transverse creases so as to be expandable and contractible between the carriage and the respective first and second end walls as the carriage reciprocates between the first and second ends of the worm gear.

[0011] According to some aspects of the present disclosure, the carriage includes one or more downwardly depending shrouds, such as first and second side panels depending downwardly along opposite lateral sides of the reciprocating drive, to protect the linear actuator from debris. The side shields are preferably formed of a stiff material, such as metal, hard plastic, or the like. The side shields may extend down to or beyond the height of the support platform of the sled that supports the reciprocating spinner assembly. The side shields may be angled outwardly, for example, to direct falling debris away from the linear actuator.

[0012] According to some aspects of the present disclosure, one or more temperature sensors and/or temperature gauges are operatively connected with the sled assembly and arranged to sense and/or display the temperature of the spinner and/or the temperature of the reinforcing material entering the spinner, such as at an inlet into the spinner. The temperature sensors may be used to monitor the temperature and/or adjust the pressure of compressed air used to spray the reinforcing material and rotate a rotatable spray head of the spinner, for example, to prevent the air compressor from causing freezing of the spray head during hot weather.

[0013] According to some aspects of the present disclosure, one or more air pressure sensors and/or pressure gauges are operatively connected with the sled assembly and arranged to sense and/or display the pressure of compressed air for the spinner. Preferably, at least one air pressure sensor is arranged to sense the pressure of the compressed air entering or inside of the spinner.

[0014] According to some aspects of the present disclosure, one or more visual indicators, such as one or more lights, which may include similarly or, alternately different colored lights, are arranged to provide a visual indication of which direction the carriage is moving along the worm gear, thereby providing a visual cue as to whether the spinner is applying material in a radial direction while moving toward the view or away from the viewer (or, in the case of a remotely-monitored sled system, toward or away from a video camera). In some arrangements, a first light of a first color, such as a red light, is turned on when the carriage is moving toward the first end of the worm gear. In some arrangements, a second light of a second color, such as a blue light, is turned on when the carriage is moving toward the second end of the worm gear. The first and second lights may be alternatingly activated and deactivated, for example, with the one or more proximity switches arranged to sense the proximity of the carriage along the worm gear.

[0015] In further accordance with any one or more of the foregoing aspects and exemplary arrangements, a sled assembly according the teachings of the present disclosure may include any one or more of the reciprocating spinner assembly, the sled, and any one or more of the aspects and features described herein. The reciprocating spinner assembly may be carried by the sled. One or more connectors may be provided for operatively connecting the spinner to a supply of reinforcing material to be sprayed from the rotating spray head, a supply of compressed air, a supply of electrical power, and/or data communication lines. The sled assembly may be moved axially along the interior of a pipe, such as by being pulled by a cable or chain with a retrieval mechanism, such as a winch or planetary gear retrieval mechanism.

[0016] Other viable aspects and optional forms of the sled assembly, sled, reciprocating spinner assembly, spinner and/or features thereof disclosed herein will be apparent upon consideration of the following detailed description and the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a cutaway perspective view of an apparatus for spraying reinforcing material onto an interior surface of a pipe, including a sled assembly according to the teachings of the present disclosure and operatively disposed in a pipe for forming a liner on an interior surface of the pipe;

[0018] FIG. 1A is an enlarged perspective view of the sled assembly of FIG. 1; [0019] FIG. 2 is a detailed cross-section of a ski of the sled assembly along the line 2-2 in FIG. 1A;

[0020] FIG. 3 is an exploded isometric view of the sled assembly;

[0021] FIG. 4 is a partially exploded isometric view of a reciprocating drive assembly for a reciprocating spinner assembly carried by the sled;

[0022] FIG. 5 is an end view of the reciprocating drive assembly of FIG. 4;

[0023] FIG. 6 is a top plan view of the reciprocating drive assembly with a flexible shield removed to view the interior portions thereof;

[0024] FIG. 7 is a side elevation view of the reciprocating drive assembly with the flexible shield removed;

[0025] FIG. 8 is a bottom plan view of the linear drive mechanism;

[0026] FIG. 9 is an end elevation view of the sled assembly, with broken lines illustrating intermediate and full expansion positions of the adjustable frame members and skis;

[0027] FIG. 9A is an enlarged detail view from FIG. 9 of a display panel of the sled assembly;

[0028] FIG. 9B is an enlarged detail view of an optional fastening assembly as seen along lines 9B-9B in FIG. 9;

[0029] FIG. 10 is an enlarged detail isometric view of a fastening assembly of the sled frame members near a ski of the sled;

[0030] FIG. 11 is a detailed cross-sectional view of the fastener along the lines 11-11 in FIG. 10; and

[0031] FIG. 12 is an enlarged view of a suitable lock illustrated in of FIGS. 1A, 10, and 11, in the form of a scaffold clip. DETAILED DESCRIPTION

[0032] Turning now to the drawings, FIG. 1 illustrates an exemplary arrangement of a system and apparatus for spraying reinforcing material, such as cementitious material, concrete, tar, fiberglass, or other similar flowable and/or sprayable reinforcing materials, onto an interior surface of a pipe 20 according to one or more teachings of the present disclosure. The system and apparatus includes a sled assembly 22 for spraying the reinforcing material radially onto the interior surface of the pipe 20, and a retrieval mechanism 24, for moving the sled assembly 22 axially along the length of the interior of the pipe 20. The retrieval mechanism 24 is preferably a planetary gear retrieval system as disclosed in detail in U.S. Application No. 61/636,386 filed April 20, 2012, which is incorporated herein in its entirety. The retrieval mechanism 24, however, may take other forms, such as a winch, and arrangements suitable for moving the sled assembly 22, such as by pulling and/or pushing by means of a drive connection 26, such as a cable, shaft, or chain, the sled assembly 22 along the axis of the interior of the pipe 20. Preferably, the retrieval mechanism 24 moves the sled assembly 22 at a rate of speed that may be controlled and/or adjusted so as to insure that the interior of the pipe 20 is coated with a pre-selected thickness of reinforcing material, such as from between about ½ of inch to 6 inches, to 12 inches or more, and any thickness therebetween. As the retrieval mechanism 24 is not the subject of the details of the present disclosure, further description is not provided herein; however, reference is made to the U.S. patent application No. 61/636,386 if further details are desired by the reader.

[0033] As is generally understood in the art, when it is desired to coat the interior surface of the pipe 20 with a reinforcing material, such as cement, concrete, tar, fiberglass, adhesive, and/or other similar materials, each of the sled assembly 22 and the retrieval mechanism 24 is placed in the interior of the pipe 20. The retrieval mechanism 24 is secured in a single location, such as with fasteners or other means, to the interior of the pipe at one end of a desired length or run of the pipe that is to be coated. The sled assembly 22 is initially located at the opposite end of the length or run of pipe to be coated and is movably, such as slidably, disposed on the interior of the pipe 20.

[0034] The sled assembly 22 includes a sled 28 and a spinner assembly 30 carried by the sled. Preferably, the spinner assembly 30 is a reciprocating spinner assembly, which is arranged to reciprocate back and forth on the sled 28 aligned with the central axis of the pipe 20, for example, so as to apply the reinforcing material in a feathered or layered manner. The sled assembly 22 is operatively connected to sources of reinforcing material, compressed air, electricity, and/or data communication lines such as through supply lines 32a, 32b, and 32c operatively connected to ports, such as connectors 34a, 34b, and 34c, respectively. For example, the supply line 32a is connected to a source of reinforcing material, such as a truck (not shown) carrying wet cement, to provide the reinforcing material to the spinner assembly 30. The supply line 32b is connected to a source of compressed air, such as an air compressor, to supply compressed air to the spinner assembly 30. The supply line 32c conveys electrical power, such as through wires connected to an electrical source to the spinner assembly 30. The supply line 32c optionally may include digital data communication lines for connection, for example, with one or more control and/or monitoring devices, such as a computer, electrical control circuits, display devices, and the like. Wireless control and/or monitoring devices may be employed instead of, or in addition to, wired or lined control or monitoring devices.

[0035] As best seen in FIGS. 1A and 3, the spinner assembly 30 includes a spinner 36 coupled to a carriage 38 and a linear reciprocating drive 40, or "slider," operatively coupled to the sled 28. The linear reciprocating drive 40 is arranged to reciprocate the carriage 38 and the spinner 36 linearly back and forth along an axis 42. The spinner 36 includes a rotatable spray head 44, which extends beyond a trailing end of the sled 28 and is arranged to spray the reinforcing material received from the supply line 32a radially outwardly while simultaneously spinning axially about the axis 42 or another axis parallel thereto, so as to spray the reinforcing material radially outwardly toward the interior surface of the pipe 20, as shown diagrammatically in FIG. 1. The spinner 36 preferably uses the compressed air supplied from supply line 32b to eject the reinforcing material at a high velocity through the rotatable spray head 44 and simultaneously to cause the rotatable spray head 44 to rotate such as by spinning about its axis due to jet propulsive forces caused by the high velocity ejection of the compressed air and reinforcing material through the rotatable spray head 44.

[0036] As best seen in FIGS. 3 and 4-8, the linear reciprocating drive 40 includes a worm gear 46 linearly aligned with the axis 42 and rotatably carried within a bracket 48, a reversible drive motor, such as a servo motor 50, and a threaded carriage support 52 threadably engaged with the worm gear 46. The carriage 38 and the threaded carriage support 52 may be separate pieces that are subsequently fastened together, for example with bolts, screws, or claims, or may be a single unitary piece. The bracket 48 includes a bottom wall 48c and two end walls 48a and 48b on opposite ends of the worm gear 46 and a pair of rails 54 aligned axially on opposite sides of the worm gear to slidably guide the threaded carriage support 52 axially along the length of the worm gear 46. The worm gear 46 extends axially along the bracket 48 between opposite first and second ends. The ends of the worm gear 46 define a maximum travel distance along a reciprocating travel path for the threaded carriage support 52 axially back and forth along the length of the worm gear 46. The opposite first and second ends of the worm gear 46 are journaled, for example, to opposing first and second thrust bearings 49 carried by the bracket 48. The thrust bearings 49 are secured, for example, to the bottom wall 48c spaced inwardly from the end walls 48a and 48. In other arrangements, the thrust bearings 49 may be disposed in or at the end walls 48a and/or 48b.

[0037] The servo motor 50 is connected to the bracket 48, such as with a flange and/or to the end wall 48a adjacent the first end of the worm gear 46. The servo motor 50 includes or is operatively connected with a DC controller and is operatively connected to the worm gear 46 so as to be able to rotate the worm gear 46 in both a clockwise and a counterclockwise direction to move the threaded carriage support 52 back and forth along the reciprocating travel path. When the servo motor 50 rotates the worm gear 46 in a first direction, the worm gear 46 moves the threaded carriage support in a first direction toward the first end of the bracket 48. The threaded carriage support 52 includes a threaded bore that receives the worm gear 46 and first and second guide members 52a and 52b that are slidably secured to the rails 54 on opposite sides of the worm gear 46 to prevent rotation of the carriage support 52. Thus, the threaded carriage support 52 is arranged to be moved axially in a first direction toward the first end of the worm gear 46 by threaded interaction when the worm gear is rotated by the servo motor 50 in a first rotational direction. When the servo motor 50 rotates the worm gear 46 in the opposite rotational direction, the worm gear 46 moves the threaded carriage support 52 axially in a second direction toward the second end of the worm gear 46. In one arrangement, a suitable linear reciprocating drive 40 is a model XLA 14 linear actuator available fro Specialty Motions, Inc., of Corona, California.

[0038] One or more, and preferably two, proximity switches 56a and 56b are disposed along the reciprocating travel path of the threaded carriage support 52. The proximity switches are arranged to cause the servo motor 50 to reverse direction and thereby cause the carriage 38 and the spinner 36 to reverse direction at each opposite end of the reciprocating travel path, for example, by providing appropriate signals to the DC controller for the servo motor 50. The proximity switches 56a and 56b are shown at opposite ends of the reciprocating travel path, however other arrangements may also be suitable as would be understood in the art. As the threaded carriage support 52, the carriage 38, and the spinner 36 move toward one proximity switch, such as proximity switch 56a, the proximity switch provides a signal to cause the servo motor 50 to change rotational directions and thereby cause the spinner 36, carriage 38, and threaded carriage support 52 to reverse directions and travel toward the opposite end of the worm gear. Similarly, the proximity switch 56b provides a signal to the servo motor 50 to cause the spinner 36, carriage 38, and threaded carriage support 52 to reverse direction in a similar manner when at the second end of the path of travel. The signals may be provided directly to the servo motor 50 and/or may be provided to an electronic controller or other electrical circuit arranged to provide control signals to the servo motor 50. The proximity switches 56a and 56b may be, for example, GX-H8A inductive proximity sensors available from Panasonic USA, similar proximity sensors, and other types of proximity sensor switches capable of functioning as described herein.

[0039] A shield, such as an accordion style dust cover 58, covers the worm gear 46 to minimize the exposure of the worm gear 46 to debris such as dust and/or overspray or other particles from the reinforcing material being sprayed from the rotatable spray head 44, for example. The dust cover 58 is preferably flexible, for example, made of cloth or flexible plastic. The dust cover 58 extends from the first end of the bracket 48 to the second end of the bracket 48, for example connected to the opposite end walls 48a and 48b. In one arrangement, the dust cover 58 includes a first portion 58a and a second portion 58b. The first portion 58a extends from the first end wall 48a to a first side of the threaded carriage support 52. The second portion 58b extends from a second side of the threaded carriage support 52 to the second end wall 48b. Thus each portion 58a and 58b of the dust cover 58 includes a first end connected to the threaded carriage support 52 and the second end connected to the adjacent end wall of the bracket 48. Preferably each of the first and second portions 58a, 58b has a channel shape cross-section, such as an upside down U-shape cross section, forming a top wall to cover the worm gear 46 and two side walls depending downwardly from opposite sides of the top wall to the bottom wall of the bracket 48. Thus, the dust cover 58 can completely enclose the worm gear 46 in conjunction with the bracket 48 to protect the worm gear 46 from dust and debris.

[0040] Each portion 58a, 58b is formed in an accordion manner, that is, including a plurality of axially spaced apart, transverse pleats or creases that allow each portion of the dust cover 58 to expand and contract axially along the length of the worm gear 46. Thus, as the threaded carriage support 52 moves, for example from the first end wall 48a toward the second end wall 48b, the first portion 58a expands axially and the second portion 58b contracts axially, thereby maintaining the worm gear 46 completely covered along the entire path of travel of the threaded carriage support 52. Similarly, the first portion 58a contracts and the second portion 58b expands as the threaded carriage support 52 travels from the second end wall 48b toward the first end wall 48a. I n some arrangements, the dust cover 58 may be formed of a single accordion style cover portion that covers the worm gear 46 and has a first end connected to the first end wall 48a and a second end connected to the second end wall 48c. In this arrangement, a hole may be cut mid way along the axial length to accommodate the threaded carriage support 52, and/or the single piece dust cover 58 may be sandwiched and/or secured between the carriage 38 and the threaded carriage support 52 such that the opposite ends of the dust cover 58 will function similarly as already described. I n this manner the shield, such as the dust cover 58 minimizes the entrance of abrasive particles that may cause damage to seals and/or other rotating and moving parts of the linear reciprocating drive 40. The dust cover 58 and/or the portions 58a and 58b, in some arrangements, are fastened to the end walls 48a, 48b and/or the threaded carriage support 52 with re-fastentable fasteners, such as hook and loop connectors or screws.

[0041] As best seen in FIGS. 1A, 3, and 9, one or more downwardly depending shrouds 59, such as in the form of side panels, extend downwardly from the carriage 38. The shrouds 59 are arranged to protect the reciprocating drive 40 from flying dirt and debris. The shrouds 59 also provide additional shielding of the accordion-style dust cover 58 and the worm gear 46. Preferably, each shroud 59 overlaps and covers the entire space along the lateral sides of the spinner assembly 30 between top wall of the carriage 38 and a support platform 60 for supporting the spinner assembly 30. A first shroud 59 depends downwardly from a top wall of the carriage 38 along a first lateral side of the reciprocating drive 40. A second shroud 59 depends downwardly the top wall of the carriage along the opposite lateral side of the reciprocating drive 40. Each shroud 59 extends axially along the entire length of the carriage 38 and the entire axial length of the bracket 48. In this arrangement, the carriage 38, including the shrouds 59, completely covers the top and lateral sides of the reciprocating drive 40. The shrouds 59 may be slanted, such as being angled outwardly and downwardly from the top wall of the carriage 38, which may help direct falling debris away from the reciprocating drive 40. Preferably, each shroud extends down at least to the level of the support platform 60 and in some arrangement extends past and below the support platform 60. The shroud 59 are preferably formed of a rigid material, such as metal plates or hard plastic panels. The shrouds 59 may be formed as a unitary portion of the carriage 38 or may be separate from the carriage 38. Each shroud 59, for example, may be in the form of a metal wall fastened to the lateral edge of the top wall by welding. In another arrangement, for example, the carriage 38 may be formed of a single channel member, for example, wherein the shrouds 59 are the side walls of a U-shaped or C-shaped channel section and the spinner 36 is secured to the web or base portion of the U-shaped or C-shaped channel section.

[0042] As best seen in FIGS. 1A and 3, the sled 28 includes the support platform 60, which carries the spinner assembly 30, a pair of skis 62 for sliding across the interior surface of the pipe wall, and at least one and preferably two adjustable frames 64 connecting the skis 62 to the support platform 60. Each frame 64 is preferably in the form of a triangular frame including first and second leg member 66a, 66b extending from the support platform 60 to one of each of the skis 62, and a cross member 68 extending from one ski 62 to the opposite ski 62. Preferably, the legs 66a and 66b and the cross member 68 of each frame 64 are aligned within a single plane, which may be orthogonal to the axis 42. Each leg 66a and 66b is angled outwardly from the support platform 60 to the respective ski 62. Each leg 66a and 66b is formed of a first strut member 70, such as a first straight tube, and a second strut member 72, such as a second straight tube, that is slidably engaged with the first strut member 70. The first and second strut members 70, 72 can slide axially along one another to extend or contract between a plurality of different lengths. In a similar manner, each cross member 68 is adjustable between a plurality of different lengths. For example, each cross member 68 includes a central tube 74 having a first end that slidably receives a laterally projecting tube 76 from the first ski 62a and a second end that slidably receives a second tube 78 projecting laterally from the second ski 62b toward the first ski 62a. An axial brace 80 extends axially and is connected to each of the tube members 74 along the axial direction to provide added stability and strength to the sled.

[0043] As best seen in FIG. 9, each of the legs 66a and 66b and the cross members 68 may be extended or retracted so as to be able to selectively locate the spinner 36 at any of a plurality of different radii, for example, Rl, R2, and R3, and thereby adjust the height of the sled 28 to place the spinner 36 at the center of different diameter pipes. Further, as best seen in FIGS. 9B and 10, each of the legs 66a, 66b is rotatably coupled, such as with a bolt 86 or other pin, to the support platform 60, and optionally to the cross member 68 such as with a similar bolt 86 or other pin connection with the first and second tubes 76 and 78 respectively. Thus, the angles of the leg members 66a and 66b and the cross member 68 of triangular frame 46 may also be selectively adjusted, for example to accommodate different sizes and shapes of pipe.

[0044] Each of the legs 66a, 66b and the cross member 68 includes a locking mechanism to selectively lock the respective legs and cross member at a selected length. For example, each of the strut members 70 and 72 and tubes 74, 76, and 78 includes one or more apertures 82 which can be selectively aligned with each other at various lengths. A locking pin, such as a standard scaffolding clip 84, as best shown in FIGS. 10-12, is inserted through an aligned set of apertures 82 to lock the legs 66a, 66b and the cross member 68 at a selected length.

[0045] Each of the skis 62a and 62b is preferably formed of a structural core 88, such as an elongate metal tube, and an outer wear cover 90, such as a polymer channel, arranged to slidably engage against the interior surface of the pipe 20. The wear cover 90 is disposed along at least the bottom surface of the tube 88 and preferably includes a bottom wall forming the bottom surface and two side walls that encase the opposite side walls of the tube 88, as best seen in FIGS. 2, 3, and 10. The wear cover 90 is secured to the structural core 88, for example with fasteners 92, such as bolts 86 or scaffold clips 84. Preferably the wear cover 90 is releasably secured to the tube 88 so that it can be easily changed. Thus, when the wear cover 90 becomes excessively worn due to friction against the interior surface of the pipe 20 or for other reasons, the wear cover 90 can be easily changed and replaced with a new wear cover, without having to repair or replace the underlying structural core 88. In some arrangements, the wear cover 90 is a channel member formed of nylon. The exposed surface of the wear cover 90 also serves to reduce friction between the skis 62a, 62b and the interior surface of the pipe 20. [0046] At least one, and preferably two or more temperature sensors 94 are arranged to sense the temperature of the spinner 36 and the temperature of the reinforcing material entering the spinner. Thus, a first temperature sensor 94 is operatively disposed at the connector 34a so as to sense the temperature of incoming reinforcing material from the supply line 32a as the reinforcing material enters the spinner 36. A second temperature sensor 94 is operatively disposed on the spinner 36 so as to sense the temperature of the spinner. The temperatures sensors 94 may be or include, for example, potentiometers, such as an RV 20M potentiometer. An air pressure sensor 95 is operatively arranged to sense the pressure of the compressed air at the spinner 36. The temperature sensors 94 are particularly useful for adjusting the pressure of the compressed air provided to the spinner assembly so as to prevent freezing of the spinner assembly and/or the reinforcing material on hot days and the like. In some arrangements, this is accomplished automatically, such as by means of a computer and/or other central processing unit arranged to receive the temperature signals from the temperature sensors 94 and/or the air pressure sensor 95 and transmit control signals, for example by means of data transmission wires through the supply line 32c, to an air compressor (not shown) to adjust the compression of the air delivered through the line 32b. In other arrangements, adjustment of the air pressure may be performed manually by an operator reading temperature readings and air pressure readings provided from the temperature sensors 94 and the air pressure sensor 95. Thus in one arrangement, one or more temperature gages 96 and air pressure gages 98 are provided as a part of the sled assembly 22, such as on a display panel 100 disposed at a leading end of the sled 28. The display panel 100 has a top end connected to the support platform 60 and a bottom end that depends downwardly from the support platform 60. The temperature gauges 96 are operatively connected with the temperature sensors 94 to provide a temperature reading of the incoming reinforcing material and of the spinner 36. The air pressure gauge 98 is operatively connected with the air pressure sensor 95 along the flow path of the compressed air so as to display the pressure of the compressed air at the spinner 36. [0047] One or more visual indicators, such as lights 102a and 102b, are preferably provided on the sled assembly and arranged to provide a visual indication to an operator of which direction the carriage 38 and the spinner 36 are moving on the linear reciprocating drive 40. The first light 102a may be a first color, such as red, and the second light 102b may be a second color such as blue. The lights 102a and 102b turn off and on alternatingly depending on which direction the spinner 36 and carriage 38 are moving on the linear reciprocating drive 40. For example, when the carriage 38 is moving toward the first end wall 48a of the bracket 48, the light 102a is turned on and the light 102b is turned off. When the spinner 36 and carriage 38 are moving along the linear reciprocating drive 40 toward the second end wall 48b of the bracket 48, the light 102b is turned on and the light 102a is turned off. The visual indicators may be activated by means of the position sensors 56a and 56b. Thus for example when the threaded carriage support 52 approaches the proximity sensor 56a, the light 102a is turned off and the light 102b is turned on by means of an appropriate electrical circuit. When the threaded carriage support 52 approaches the proximity sensor 56b, the light 102a is turned on and the light 102b is turned off by the same or a similar electrical circuit in any manner that would be understood in the art. The lights 102a and 102b can provide visual confirmation to an operator that the spinner 36 is reciprocating back and forth on the sled 28 even when the sled 28 is a significant distance away from the operator down the pipe 20, for example, or alternatively in the case of a remotely-monitored sled, a significant distance away from a video camera. Thus, for example, if the operator notices that the lights 102a and 102b are not switching on and off in appropriate time periods, the operator knows to stop the coating process and check the entire sled assembly for any malfunctions.

[0048] One or more lamps 104, such as flood lights or spot lights, are optionally arranged on the sled assembly 22 so as to light the work area around the sled in a manner that will allow an operator to visually inspect the progress of work around the sled. Preferably, the lamps 104 are arranged toward the trailing end of the sled 28 so as to illuminate the area where the reinforcing material is being applied to the interior of the pipe 20. The lights 104 are preferably disposed on opposite lateral sides of the support platform 60 near the leading end of the sled 28 and arranged to shine beams of light axially toward the trailing edge of the sled 28. Additional lights may be provided with the sled assembly 22 and may be controllable so as to turn on and/or off to illuminate other areas along the sled 28. The lights 104 allow an operator to visually inspect the progress of work surrounding the rotatable spray head 44 and behind the trailing edge of the sled assembly 22 without having to carry or shine a separate lantern or high-intensity light source down the length of pipe 20.

INDUSTRIAL APPLICABILITY

[0049] An apparatus and system according the teachings of the present disclosure in some arrangements is useful for spraying reinforcing materials onto an interior surface of a pipe as described in the technical example provided herein. However, the apparatus may have additional and/or alternative beneficial uses.

[0050] The technical examples described and shown in detail herein are only exemplary of one or more aspects of the teachings of the present disclosure and are presented for the purpose of teaching a person of ordinary skill some optional ways to make and use the invention or inventions recited in the appended claims. Additional aspects, arrangements, forms, and/or benefits of the invention or inventions within the scope of the appended claims are contemplated, the rights to which are expressly reserved.

Claims

WHAT IS CLAIMED:

1. A reciprocating spinner assembly for spraying reinforcing material against the inner surface of a pipe, comprising: a linear actuator comprising an axial worm gear operatively connected to a reversible drive motor; a carriage operatively connected to the axial worm gear; and, a spinner carried by the carriage, wherein the reversible drive motor rotates the axial worm gear in alternating directions to reciprocate the carriage and the spinner in a first direction and a second direction along a path of travel disposed axially along the axial worm gear.

2. The reciprocating spinner assembly of claim 1, wherein the spinner comprises: a rotatable spray head arranged to spray the reinforcing material received from a supply line radially outwardly while simultaneously spinning axially about an axis so as to spray the reinforcing material radially outwardly toward the interior surface of the pipe.

3. The reciprocating spinner assembly of claim 1 or any one of the previous claims, wherein the spinner uses compressed air to eject the reinforcing material at a high velocity through the rotatable spray head and simultaneously to cause the rotatable spray head to rotate.

4. The reciprocating spinner assembly of claim 1 or any one of the previous claims, wherein the reversible drive motor is a servo motor.

5. The reciprocating spinner assembly of claim 1 or any one of the previous claims, wherein a first end of the worm gear is journaled to a first thrust bearing and a second end of the worm gear journaled to a second thrust bearing, wherein the first and second thrust bearings are secured to the bracket.

6. The reciprocating spinner assembly of claim 1 or any one of the previous claims, further comprising one or more proximity switches disposed along a path of travel of the carriage and arranged to cause the reversible drive motor to reverse direction and thereby cause the carriage and the spinner to reverse direction at opposite ends of the path of travel.

7. The reciprocating spinner assembly according to claim 1 or any one of the previous claims, further comprising a flexible shield covering the worm gear to minimize exposure of the worm gear to debris.

8. The reciprocating spinner assembly according to claim 7 or any one of the previous claims, wherein the shield comprises an accordion dust cover that extends to opposite first and second ends of the worm gear and has an axial channel shape, including a top wall and two downwardly depending sidewalls along opposite transverse sides of the top wall, and a plurality of transverse pleats that allow the accordion dust cover to expand and contract axially along the length of the worm gear.

9. The reciprocating spinner assembly of claim 8 or any one of the previous claims, wherein the shield includes a first section and a second section disposed on opposite sides of the carriage, the first section having a first end connected to a first side of the carriage and a second end connected to a first end wall disposed at the first end of the worm gear, and the second section having a first end connected to a second side of the carriage and a second end connected to a second end wall disposed at the second end of the worm gear.

10. The reciprocating spinner assembly of claim 1 or any one of the previous claims, further comprising a shroud arranged along a side of the carriage to protect the linear actuator from flying debris.

11. A sled for carrying a reciprocating spinner assembly according to any one of the previous claims, the sled comprising: at least one ski for slidably supporting the sled assembly on the interior surface of a pipe, each of the at least one skis including an axially elongate structural core member and an outer wear cover disposed along a bottom surface of the elongate structural member, wherein the outer wear cover is releasably secured to the outer surface of the structural core member with fasteners.

12. The sled of claim 11 or any one of the previous claims, wherein the axially elongate structural core member comprises a metal tube, the outer wear cover comprises a polymer channel, and the fasters comprise at least one of screws, bolts, and clips.

13. The sled of any one of claims 11 to 12 or any one of the previous claims, wherein the sled includes two of the skis and a triangular frame with adjustable frame members that can be selectively lengthened and shorted in a vertical and a horizontal direction to move a support platform for the reciprocating spinner assembly upwardly and downwardly from the two skis, whereby the triangular frame that can be selectively adjusted to maintain the spinner generally radially centered within pipes of different sizes.

14. The sled of claim 13 or any one of the previous claims, wherein the adjustable frame members may be locked into a selected length with scaffold clips.

15. A sled assembly comprising a sled comprising at least one ski for slidably supporting the sled assembly on the interior surface of a pipe, each of the at least one skis including an axially elongate structural core member and an outer wear cover disposed along a bottom surface of the elongate structural member, wherein the outer wear cover is releasably secured to the outer surface of the structural core member with fasteners; and a reciprocating spinner assembly carried by the sled.

16. The sled assembly of claim 15, wherein the reciprocating spinner assembly comprises: a linear actuator comprising an axial worm gear operatively connected to a reversible drive motor; a carriage operatively connected to the axial worm gear; and, a spinner carried by the carriage, wherein the reversible drive motor rotates the axial worm gear in alternating directions to reciprocate the carriage and the spinner in a first direction and a second direction along a path of travel disposed axially along the axial worm gear.

17. A sled assembly according to any one of claims 15 and 16, further comprising: a first temperature sensor operatively connected to sense the temperature of reinforcing material entering the spinner.

18. A sled assembly according to any one of claims 15 to 17, further comprising: a second temperature sensor operatively connected to sense the temperature of the spinner.

19. A sled assembly according to any one of claims 15 to 18, further comprising: a temperature gauge arranged to display the temperature of at least one of the spinner and the reinforcing material entering the spinner.

20. A sled assembly according to any one of claims 15 to 19, further comprising: an air pressure sensor operatively connected to sense the air pressure of compressed air for the spinner.

21. A sled assembly according to claim 20, further comprising: an air pressure gauge arranged to display the air pressure of the compressed air for the spinner.

22. A sled assembly according to any one of claims 15 to 21, further comprising: a visual indicator arranged to provide a visual indication of which direction the carriage is moving along the worm gear.

23. A sled assembly according to claim 22, wherein the visual indicator includes a first light that is turned on when the carriage is moving toward a first end of the worm gear, and a second light that is turned on when the carriage is moving toward the second end of the worm gear, wherein the first and second lights are alternatingly activated and deactivated.