This report presents the development of a conceptual design for an automated system that feeds, mounts, and dismounts CPT tubes into a Push Frame, addressing the limitations of current manual operations at Geomil. The project aimed to create a reliable, safe, and efficient solution for the tube handling process, with a focus on automation of both positioning and (dis)mounting operations. The design process began with an analysis of the current state of the art, both internally at Geomil and externally in similar applications, to identify existing methods, limitations, and opportunities for automation. Functional requirements, boundary conditions, design limitations, and user preferences were established to guide concept generation and evaluation. Using a morphological analysis and multi-criteria scoring, multiple concepts were developed for positioning mechanisms and (dis)mounting systems. After evaluation, the best concepts were a Robotic Arm for positioning and a Raptor with Clamping blocks for (dis)mounting. After the preliminary designs were made, it was chosen that the Robotic Arm would be replaced with a Rail Gantry.
The final design integrates four key subsystems: a tube storage with charging modules, a Rail Gantry, the Raptor with clamping blocks, and a PLC-based control and safety system. The system allows sequential and reversible operation, enabling automated retrieval, connection, insertion, and storage of standard and casing tubes. Safety, maintainability, and operational efficiency were emphasized through features such as protective fencing, emergency stops, modular components, and intuitive control interfaces.
Strengths of the system include high precision, modularity, and adaptability to different tube types, as well as future-proofing for electronic tube monitoring and recharging. Limitations include higher initial cost, space usage in a vehicle, and a lower operation time per tube. The operation time analysis shows that, under standard settings, the automated system requires 60–70 minutes per full cycle of 30 tubes compared to 45 minutes for manual operation. Where the longer time is for serial operation and the shorter time is for parallel operation, where multiple actions are performed at the same time. However, with a higher motor speed and longer tubes, the cycle time can be reduced to 33.33-40 minutes, outperforming manual operation. The total production and assembly cost of the system is approximately €30,700, leading to a sales price of around €86,000. Although this represents a significant initial investment, the ROI analysis indicates a payback period of roughly one year, after which the system provides substantial long-term economic and ergonomic benefits.
Overall, the proposed system demonstrates a viable, innovative solution for fully automated tube handling in a vehicle-mounted environment, reducing manual labor, improving safety, and ensuring reliable and accurate operation. The report concludes that automated feeding and mounting of CPT tubes is achievable, practical, and adaptable to various operational scenarios, offering significant improvements over current manual processes.