38 n GEARS AND GEARBOXES January 2026 www.drivesncontrols.com Weld-fixing system relies on tough spiral-bevel gears Essex-based Optical Metrology Services (OMS) has developed a robotic crawling device that tackles welding defects inside pipes at an early stage. The inspection and remediation device, called Smartgrind, is typically applied in hard-to-reach areas of renewable and traditional energy structures, where weld defects can cause catastrophic structural failures, leaks and operational shutdowns. SmartGrind is a modular add-on to OMS’s AUGA.node visual and laser inspection system, which identifies and solves weld defects at an early stage, thus ensuring that potential problems are remediated rapidly. The device, equipped with camera and laser sensors, scans welds inside the pipework and identifies any issues, after which it can carry out local remediation using a mounted flap disc that shapes the welds, thus improving their coatability, strengthening surfaces, and helping to ensure that project specifications are met. Spatter The SmartGrind system can carry out repairs on defects such as spatter and excess penetration, before re-scanning to confirm the weld quality. When deployed on a crawler mechanism, it can navigate through elbows, around bends and up vertical sections in pipes. It can also be attached to an internal line-up clamp (Iluc) – a tool used to align two sections of pipe from the inside before they are welded together – or deployed via push-rods. The SmartGrind system can solve weld defects in situ, without needing to make cutouts in the pipes. According to OMS, it allows users to build stronger, longer-lasting pipelines, and ensures that welds meet specifications, thus saving money and reducing downtime. The technology eliminates the need for human operation in hazardous environments, and improves worker safety. When designing the SmartGrind system, OMS needed strong, reliable gears for its proprietary grinding system that would be able to withstand challenging conditions, such as severe weather conditions, extreme temperatures and 24/7 operation. The gears would also need to perform reliably in awkward locations. “Our grinding system is ground-breaking technology that uses a robotic crawler to deploy targeted smart remediation services within pipelines, particularly to areas that are hard to access,” explains OMS’ chief design engineer, Jack Parlane. OMS turned to RA Rodriguez (UK) to supply precision-engineered spiral-bevel gears made by the Japanese gear producer, KHK. The gears have been hardened to increase wear resistance, and ground to improve their precision and surface finish after heat treatment, thus enhancing durability, reducing noise and vibration, and increasing the lifespan of the gear. “Maintaining strength and reliability are vital for our services, which operate in critical energy production environments, so KHK gears were the ideal choice for us,” says Parlane. Successful projects Since launching SmartGrind in 2023, OMS has seen growing success for the system. In January 2025, it was approved by Saudi Aramco, following a qualification trial with CRTS Global, and having completed several successful projects. The system is now being deployed on multiple installations. ‘We identified a customer need for targeted weld remediation some time ago and are delighted that SmartGrind is able to tackle client requirements so effectively,” reports OMS sales director, Paul Eagle. “We’ve seen demand for it grow significantly and we expect that to increase in 2026. Having the ability to identify and resolve any weld issues at an early stage has helped our clients ensure their pipes are in the optimum condition for coating and increase installation efficiency.” n A UK company has developed a system for inspecting welds in pipes and, if necessary, fixing them. The equipment incorporates a grinding system that needed gears that would operate reliably is tough operating conditions, including high temperatures and hard-to-access locations. The complex, but rugged, SmartGrind system has been designed operate reliably in demanding environments The system inspects welds inside pipes and, if necessary fixes any problems, improving structural integrity, enhancing safety and cutting downtime.
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