Electric Internal Debeader

THE CONTEXT

Internal Debeading for HDPE Pipe

RESEARCH

The research involved interviews with experienced HDPE pipe debeading operators and observational studies to identify key challenges in the current process. Findings highlighted excessive physical strain, inefficiencies, and safety risks with manual tools, particularly in confined spaces. This research informed the need for ergonomic enhancements, automation, and technology integration to improve efficiency and operator safety. The research interviews provided insight into these current problems faced in the industry and the observations of current processes, videos analysis and live demos all played a key role in shaping these findings. Presently more is needed to be done to streamline the debeading process and make it safer for opearators around the country.

Current Conditions for a lot of operators out on site in industries such as oil, mining and gas.

‘Every one of those joins is that little bit more torsion and that little bit more movement. And when you get them smoosh, and they don’t actually cut get in underneath it nicely, and they’re just like trying to turn this molten wall off plastic.’

Research Interviewee

The main issue is clearly highlighted in this image showcasing how currently the Debeading process results in excessive physical strain, inefficiencies, and safety risks with the manual tools used currently.

‘Some type of visual device, ie camera, with a headlight on it, so you can see the process the operators outside of it, and then just connect to their phone or something similar’.

Research Interviewee

During the research process key points to draw upon became clear and the need for innovation in the Debeading space was a key standout. The quote above from one of the two interviewees really underlines the clear want and need for common place innovation technology such as Wifi Camera/ Light Combos to be applied to the Debeading setting.

KEY ISSUES HIGHLIGHTED:

1. Physical Exertion: Operators using manual debeading tools report needing to exert up to 30% more physical effort in confined spaces and on larger-diameter pipes (Ritmo, 2023). This leads to increased fatigue and a higher risk of injury.


2. Efficiency Drop: Observations showed that manual debeading can take up to twice as long compared to semi-automated processes, highlighting an opportunity to significantly improve workflow (R&L Manufacturing, 2024).


3. Safety Risks: Over 40% of operators in confined-space debeading reported near-miss incidents, underlining the critical need for safer, ergonomic tool designs (US Fusion, 2023).

RESEARCH REPORT DOWNLOAD

Breaking Down the Final Design

Showcases the sleek finish of the design and also showcases the adjustable nature of the spinning Debeading cutting head. Seen above is the powerful light/ camera combo that allows for traceability and reportability for the operator controlling the device.

1. Research & Analysis: Conducted in-depth interviews and observational research to identify critical challenges in the current debeading process, such as operator fatigue, safety risks, and tool inefficiencies.

2. Identifying Opportunities: Analysed findings to uncover key areas for innovation, including the need for ergonomic improvements, automated bead recovery, and advanced monitoring systems like Wi-Fi cameras.

3. Ideation & Concept Development: Generated design concepts addressing these challenges, focusing on user-centric features that enhance safety, efficiency, and ease of use.

4. Final Design: Developed a comprehensive, innovative solution incorporating Electric systems, and smart technology to meet the industry’s needs and improve operator experience and safety

Clear Story Board Renders showcasing how the product will be assembled and used.

The Video Showcases the Final Design Presentation and provides a deep dive into some of the key features of the Design such as the;

– Wifi Camera/ Light Combo that links to external devices such as the McElroy Data Logger.
– Innovative spinning Mechanism designed to drive the cutting head effectively
– Easy to connect points of contact that make the design easily compatible with most Internal Debeaders available currently.

The final concept is an industry first with real world applications screaming out for a product like this. The design was created with operators in mind as they were key to the devlopment of the concept. Numerous interviews, observations and analysis shaped this product devlopment. The design is built to last featuring a strong Aluminum housing unit that is capable and durable for any Debeading activity. The way the design connects to existing Debeaders allows it to be used across a wide variety of pipe sizes allowing for more ease of use for the operator. The Electric Internal Debeader ultimately provides significant benefits, enhancing efficiency, reducing physical strain, and improving safety, while also creating opportunities for future advancements in the industry. Such as linking this design with a McElroy Datalogger through the innovative wifi camera.