Systems and methods for providing coupling joints

Abstract

A system for providing a joint for connecting a first object and a second object includes a data acquisition device configured to acquire joint parameter data regarding the first object and the second object, and a controller coupled to the data acquisition device and configured to provide joint design data regarding a design of the joint based on the joint parameter data.

What is claimed is: 
     
         1 . A method for providing joint design data for a joint configured to couple a first object to a second object, the method comprising:
 acquiring joint parameter data regarding the first object and the second object using a data acquisition device;   transmitting the joint parameter data to a controller; and   generating joint design data based on the joint parameter data using the controller.   
     
     
         2 . The method of  claim 1 , wherein the data acquisition device includes an image sensor and wherein the joint parameter data is acquired by capturing an image including at least one of the first object and the second object using the image sensor. 
     
     
         3 . The method of  claim 2 , further comprising:
 determining a distance to at least one of the first object and the second object using the image sensor.   
     
     
         4 . The method of  claim 2 , further comprising:
 moving the image sensor to a second position after the image is captured;   determining a change in at least one of a location and an orientation of the image sensor based on the movement; and   acquiring additional joint parameter data by capturing a second image at the second position, the second image including at least one of the first object and the second object.   
     
     
         5 . The method of  claim 2 , further comprising:
 capturing a first reference within the image;   wherein the joint design data is generated based on a position of the first reference within the image.   
     
     
         6 . The method of  claim 5 , further comprising:
 capturing a second reference within the image;   wherein the joint design data is generated based on a position of the second reference within the image.   
     
     
         7 . The method of  claim 6 , further comprising:
 determining a position of the second reference relative to at least one of the first object and the second object based on the image;   wherein the joint design data is generated based on the position of the second reference relative to at least one of the first object and the second object.   
     
     
         8 . The method of  claim 6 , wherein the joint design data is generated by determining positions of the first and second objects relative to both the first reference and the second reference. 
     
     
         9 . The method of  claim 6 , further comprising:
 contacting the first object with the first reference; and   contacting the second object with the second reference.   
     
     
         10 . The method of  claim 9 , wherein the first reference includes a first code and the second reference includes a second code. 
     
     
         11 . The method of  claim 10 , further comprising:
 identifying the first and second codes;   wherein the joint design data is generated based on the first and second codes.   
     
     
         12 . The method of  claim 10 , further comprising:
 determining a dimension of the first object based on the first code; and   determining a dimension of the second object based on the second code.   
     
     
         13 . The method of  claim 6 , further comprising:
 positioning the first reference at least partially within the first object prior to capturing the image; and   positioning the second reference at least partially within the second object prior to capturing the image;   wherein the first reference is a first plug and the second reference is a second plug.   
     
     
         14 . A method for providing a joint for connecting a first pipe and a second pipe, the method comprising:
 coupling a first end of a flexible coupler to the first pipe and a second end of the flexible coupler to the second pipe;   stabilizing the flexible coupler to approximate a shape of the joint;   acquiring coupler data regarding the flexible coupler;   providing the coupler data to a controller; and   receiving the joint, wherein the joint is based on the coupler data.   
     
     
         15 . The method of  claim 14 , wherein the joint is selected from a parts catalog having a plurality of joints. 
     
     
         16 . The method of  claim 15 , wherein the joint is selected by the controller. 
     
     
         17 . The method of  claim 14 , further comprising:
 determining a custom joint design for the joint based on the coupler data.   
     
     
         18 . The method of  claim 17 , wherein the custom joint design is determined using the controller. 
     
     
         19 . The method of  claim 18 , wherein the joint is produced based on the custom joint design. 
     
     
         20 . The method of  claim 14 , wherein the joint is produced by an additive manufacturing process. 
     
     
         21 . The method of  claim 14 , wherein the joint is received from a third party associated with a producer of the joint. 
     
     
         22 . The method of  claim 14 , wherein the joint is received from a third party associated with the controller. 
     
     
         23 . A method for providing a joint for connecting a first pipe and a second pipe, the method comprising:
 coupling a first end of a flexible coupler to the first pipe and a second end of the flexible coupler to the second pipe;   stabilizing the flexible coupler to approximate a shape of the joint;   acquiring coupler data regarding the flexible coupler; and   generating joint design data usable for producing the joint based on the coupler data.   
     
     
         24 . The method of  claim 23 , further comprising:
 printing the joint based on the joint design data using a printer.   
     
     
         25 . The method of  claim 23 , wherein the coupler data is acquired by capturing an image of the flexible coupler. 
     
     
         26 . The method of  claim 25 , wherein the coupler data includes the image, and wherein the joint design data is generated based on the image. 
     
     
         27 . The method of  claim 25 , further comprising:
 removing the flexible coupler from the first pipe and the second pipe;   wherein the flexible coupler is stabilized prior to removing the flexible coupler; and   wherein the flexible coupler is removed prior to capturing the image.   
     
     
         28 . The method of  claim 25 , further comprising:
 determining a boundary condition of the joint based on the image.   
     
     
         29 . The method of  claim 23 , wherein the coupler data is acquired using a coordinate measuring machine having a probe. 
     
     
         30 . The method of  claim 29 , further comprising:
 measuring positions at multiple sites of the flexible coupler using the coordinate measuring machine;   wherein the coupler data is based on the positions.   
     
     
         31 . The method of  claim 29 , further comprising:
 de-coupling the flexible coupler from the first pipe and the second pipe prior to acquiring the coupler data;   wherein the flexible coupler is stabilized prior to de-coupling the flexible coupler from the first pipe and the second pipe.   
     
     
         32 . The method of  claim 23 , further comprising:
 selecting a suitable joint design for the joint from a database having a plurality of joint designs based on the joint design data.   
     
     
         33 . The method of  claim 23 , wherein the joint functionally connects the first pipe to the second pipe.