The disclosure relates generally to an end grooving system for tubing. More particularly, the disclosure relates to an end grooving system for tubing configured for simultaneous operation on a plurality of tubes. The disclosure also relates generally to an end grooving manufacturing process for tubing. More particularly, the disclosure also relates to an end grooving manufacturing process for tubing for simultaneous operation on a plurality of tubes in-line in a tube mill.
Typically, a pipe or tube is manufactured by taking a piece of steel strip, and rolling it into a cylinder. After rolling, the formed tube is welded using various welding techniques known in the art. Moreover, further manufacturing processes can typically be included as well. Additionally, it is often beneficial to provide a groove at the end of the tube. Typically, the process of adding the groove to the end of the tube is accomplished manually one at a time by a factory worker. This process is slow and subject to inaccuracies as well as reduced efficiencies.
Thus, there is a need to automate the end grooving process of a tube to increase speed as well as improve quality.
The foregoing needs are met, to a great extent, by the disclosure, wherein in one aspect an apparatus, system, and process is provided that implements an automated end grooving system and process for tubing.
One general aspect includes a groove forming station configured to simultaneously form a groove on an end of a plurality of tubes, including: a conveyor system configured to receive one of the plurality of tubes and align the one of the plurality of tubes for a subsequent grooving process; a first groove forming device configured to form a first groove on one end of a plurality of tubes; the first groove forming device including first inner tools configured to be each inserted into different ones of the plurality of tubes and first outer tools configured to each contact an outer surface of different ones of the plurality of tubes to form the first groove on one end of the plurality of tubes; a second groove forming device configured to form a second groove on another end of the plurality of tubes; and the second groove forming device including second inner tools configured to be each inserted into different ones of the plurality of tubes and second outer tools configured to each contact an outer surface of different ones of the plurality of tubes to form the second groove on another end of the plurality of tubes, where the conveyor system is configured to convey the plurality of tubes to the first groove forming device; and where the conveyor system being further configured to convey the plurality of tubes to the second groove forming device.
One general aspect includes a groove forming process for simultaneously forming a groove on an end of a plurality of tubes, including: receiving one of the plurality of tubes and aligning the one of the plurality of tubes for a subsequent grooving process with a conveyor system; forming a first groove on one end of a plurality of tubes with a first groove forming device; implementing the first groove forming device with first inner tools configured to be each inserted into different ones of the plurality of tubes and first outer tools configured to each contact an outer surface of different ones of the plurality of tubes to form the first groove on one end of the plurality of tubes; forming a second groove on another end of the plurality of tubes with a second groove forming device; and implementing the second groove forming device with second inner tools configured to be each inserted into different ones of the plurality of tubes and second outer tools configured to each contact an outer surface of different ones of the plurality of tubes to form the second groove on another end of the plurality of tubes, where the conveyor system is configured to convey the plurality of tubes to the first groove forming device; and where the conveyor system being further configured to convey the plurality of tubes to the second groove forming device. Other aspects include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
There has thus been outlined, rather broadly, certain aspects of the disclosure in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional aspects of the disclosure that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one aspect of the disclosure in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The disclosure is capable of aspects in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the disclosure. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the disclosure.
The disclosure will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An aspect in accordance with the disclosure provides an end grooving system and process for tubing on a production line.
The factory layout 100 may include various stations including one or more of an uncoiler station 102, a leveler station 104, an accumulator station 106, a forming station 108, a welder station 110, a cooling station 112, a sizing station 114, a cutting station 116, a grooving station 118, and a bundling station 120. However, in some aspects there may be other stations (not shown) that may be included in the factory layout 100. In some aspects the stations may be combined. In some aspects one or more stations may not be utilized in dependence on the implementation.
At the uncoiler station 102, one or more rolled steel coils may be present and ready to be uncoiled into sheets of steel. The rolled steel coils may be positioned on arms and powered by coil keepers (not shown). The coils may also be sorted into different widths or sizes in order to manufacture the desired pipe diameter and length. The rolled steel coils may be uncoiled from the coil keepers using various techniques and fed into the leveler station 104. Additionally, in one aspect, the unrolled steel coils may be joined together by welding in order to create larger sheets of steel having similar width or size. A strip flattener may be utilized to flatten the ends sufficiently for welding and then using an end welder to shear the trailing edge of the first coil and the leading edge of the next coil, so that the two pieces can be welded together.
At the leveler station 104, the uncoiled steel coils may be flattened using pinch rollers, as known in the art, and fed into an accumulator station 106. The steel coils may be accumulated at the accumulator station 106 ready to be formed into various sized pipes. Strips of the steel coils may be stored horizontally or vertically in the accumulator station 106. From the accumulator station 106, the strips of steel coil may be fed into a forming station 108, where they may be formed into tubes using a series of forming rolls by initially forming into a U-shaped and then into a cylindrical shape with open edges. The formed tubes may then be fed into the welder station 110 where the open edges are welded by heating the open edges to a welding temperature through high frequency welding, and press welded by forge rolls. After welding, the weld flash that occurred outside and inside of the pipe may be trimmed using cutting tools such as a carbide tool. Threads at each end of the pipe may also be formed. If the pipe will be used in a harsh environment, various dipping and spraying techniques and heat treatments may be utilized in order to apply protective coatings such as a rustproof coating. In addition to or alternatively, if longer lengths of piping are needed, then additional scarf welding may be performed at the welder station 110.
After the welding is performed, the welded tubes are fed into the cooling station 112 where water or other coolant may be used to cool the welded tubes. Then cooled welded tubes are fed into the sizing station 114 where the welded tubes may be sized or reshaped as needed. This process also allows for stress relief of the water tubes so that properties are normalized in the tubes. After the sizing station 114, the welded tubes may be fed into the cutting station 116, where test samples of the welded tubes may be cut using a saw and also the desired length of the tube may be cut.
After the cutting station 116, a groove may be formed at one or both ends of the tube in a grooving station 118. Alternatively, the grooving station 118 may be arranged chronologically between other stations as described herein. Details of the grooving station 118 are described in greater detail below.
Finally, the welded tubes are fed into a bundling station 120. Prior to the bundling station 120, the various pipes that were formed may be inspected and then sent to the bundler to be bundled together for shipping. It should be noted that the stations are exemplary and that the various processes that are described for each station may be performed at other stations and/or more or less stations may be utilized depending on the type of pipe being manufactured. In a particular aspect, the factory layout 100 may be implemented as a tube mill. Further in this aspect, the grooving station 118 may be implemented in the tube mill. In yet a further aspect, the grooving station 118 may be implemented in-line in the tube mill. This in-line configuration of the grooving station 118 in the tube mill provides numerous manufacturing efficiencies, reduces manufacturing time, and/or the like consistent with the disclosure.
In particular,
During the manufacturing process, the tubes 199 may be received from a conveyor system to the grooving station 118 initially at position 1 as illustrated on the left side of
The tube 199 may continue to move in the right direction from position 1, to position 2, to position 3, to position 4 with one or more conveying systems. In this regard, the tube 199 may be moved in the right direction on a stepper conveyor 208 and may be moved in groups of three. However, any number of the tubes 199 may be incrementally moved through the various positions in the grooving station 118. The stepper conveyor 208 may include a V-shaped cross-section support to ensure that the tube 199 remains in the central portion of the stepper conveyor 208. In one aspect, the stepper conveyor 208 may include three V-shaped cross-sections to ensure that three tubes 199 remain in a central portion of each of the three V-shaped cross-sections of the stepper conveyor 208.
From positions 2, 3, 4 the already aligned tubes 199 may be translated to positions 5, 6, 7. The translation of the tubes 199 through positions 5, 6, 7 may be on a chain conveyor 210. The chain conveyor 210 may include a plurality V-shaped cross-sections to ensure that each tube 199 remains in a central portion of a V-shaped cross-section of the chain conveyor 210.
In position 5, the first tube 199 may have a groove formed thereon by the groove forming machine 200 as described in greater detail below. In position 6, the second tube 199 may have a groove formed by the groove forming machine 200 thereon as described in greater detail below. In position 7, the third tube 199 may have a groove formed thereon by the groove forming machine 200 as described in greater detail below. Accordingly, three tubes 199 may receive a groove on one end simultaneously. In this regard, the simultaneous formation of grooves on a plurality of tubes 199 results in increased manufacturing speed. Of course a different number of tubes 199 may receive a groove on one end simultaneously as well consistent with the disclosure.
In this regard, in correspondence with positions 5, 6, 7 a series of drive rollers 220 may be raised and rotated so as to allow the tools of the groove forming machine 200 to be inserted inside the tubes 199 as well as pressed against the outside of the tubes 199. Thereafter, the drive rollers 220 may be rotated and lowered so as to allow the tools of the groove forming machine 200 to be removed from inside the tubes 199. Additionally, the groove forming machine 200 may translate to and from the tubes 199 utilizing a hydraulic or electromechanical device before and after the formation of the grooves on the tubes 199. In aspects that utilize a hydraulic actuator, hydraulic power packs may be included therewith.
After formation of a groove on each of the tubes 199, the tubes 199 may move to positions 8, 9, and 10. The movement may be controlled by the chain conveyor 210. In positions 8, 9, and 10, the first tube 199, the second tube 199, and the third tube 199 may be aligned with respect to an opposite side.
In this regard, the tubes 199 in positions 8, 9, and 10 may be placed on a parallel set of conveyor rollers 212 (see
In position 11, the first tube 199 may have a groove formed thereon on an opposite end by the groove forming machine 200 as described in greater detail below. In position 12, the second tube 199 may have a groove formed on an opposite end by the groove forming machine 200 thereon as described in greater detail below. In position 13, the third tube 199 may have a groove formed thereon on an opposite end by the groove forming machine 200 as described in greater detail below.
In this regard, in correspondence with positions 11, 12, 13 a series of drive rollers 222 may be raised and rotated so as to allow the tools of the groove forming machine 200 to be inserted inside the tubes 199 as well as pressed against the outside of the tubes 199. Thereafter, the drive rollers 222 may be rotated and lowered to move the tubes 199 away from the groove forming machine 200 so as to allow the tools of the groove forming machine 200 to be removed from inside the tubes 199. In one aspect, when the drive rollers 222 are lowered they may deposit the tubes 199 on the chain conveyor 210. Additionally, the groove forming machine 200 may translate to and from the tubes 199 utilizing a hydraulic or electromechanical device before and after the formation of the grooves on the tubes 199.
In one aspect, the conveyor rollers 202, the stepper conveyor 208, the chain conveyor 210, the drive rollers 220, the drive rollers 222, and the like may each be mounted, supported, or the like on a frame 230. As shown in
In particular, as illustrated in
In particular,
The groove forming machine 400 may further include a motor 404. The motor 404 may be an electric motor having one or more gears, a transmission, and the like to rotate a shaft 410. The inner tool 406 may be rotatably connected and supported by the shaft 410 and the inner tool 406 may be rotated by the shaft 410 in response to rotation of the motor 404. In some aspects, the motor 404 may be implemented using any electromechanical, mechanical, or hydraulic type actuator.
The groove forming machine 400 may further include a hydraulic actuator 402. The hydraulic actuator 402 may be configured to be connected to a support 412 and move the support 412 vertically to place the outer tool 408 in contact with the tube 199; and the hydraulic actuator 402 may be configured to move the support 412 vertically in the opposite direction to place the outer tool 408 out of contact with the tube 199. In some aspects, the hydraulic actuator 402 may be implemented using any electromechanical, mechanical, or hydraulic type actuator.
In operation, the groove forming machine 400 operates such that the motor 404 stops rotation of the inner tool 406 while in a waiting position. The tube 199 is moved by the drive rollers 220 or the drive rollers 222 into a working position towards the groove forming machine 400 and the groove forming machine 400 may translate to insert the inner tool 406 into the tube 199. Thereafter, the motor 404 begins to rotate, which rotates the inner tool 406 as well as the tube 199.
The outer tool 408 may be lowered by the hydraulic actuator 402 and begin to form a groove at the end of the tube 199. When the diameter of the groove reaches the required diameter, the outer tool 408 and the inner tool 406 may continue to rotate for a number of additional turns around the diameter of the tube 199. Thereafter, the outer tool 408 in response to movement of the hydraulic actuator 402 may be raised.
The drive rollers 220 and the drive rollers 222 may then be rotated and the groove forming machine 400 translated from the tube 199 pulling the inner tool 406 out of the tube 199. Thereafter, the groove forming machine 400 may be placed in a waiting position. In one aspect, operation of the groove forming machine 400 may be controlled by the controller 700 illustrated in
In particular,
In particular,
In one aspect, the double cone roller 807 may be mounted on the shaft 801 that is mounted in the bushing 805. In one aspect, the double cone roller 807 may have a V-shaped cross-section to ensure that the tube 199 remains in the central portion of the double cone roller 807. The timing pulley 804 may be rotated by the timing belt 811 and the timing belt 811 may engage with a timing pulley 806 and may be mounted on another bushing 805. In some aspects, the conveyor rollers 202 may include a belt tensioner 812, a timing belt 811, a housing 810, and the like. Rotation of the conveyor rollers 202 including the double cone roller 807 may be in response to operation of a motor (not shown) and controlled by the controller 700 illustrated in
Additionally, the conveyor rollers 212 may be implemented in a similar manner to the conveyor rollers 202 with the exception that there may be three parallel sets of the conveyor rollers 202 as illustrated in
In particular,
In particular,
In particular,
In particular,
In one aspect, the arms 1108 may be pivotally connected to the conveyor system 1100. Additionally, the arms 1108 may be rotated in response to rotation of a motor 1112 and associated transmission and actuation arms, to move the arms 1108 and place the tube 199 on to the conveyor rollers 202 of the grooving station 118.
In particular,
The processor 702 may be any type of processor including a controller, programmable logic controller (PLC), microprocessor, personal computer, one more core processor, ASIC, FPGA, and the like. The memory 704 may be any type of memory including volatile and nonvolatile memory such as RAM, ROM, EPROM, flash, hard drive and the like. The memory 704, in one aspect, may include the software 706, which has computer instructions to control the operation of the groove forming machines 200 and/or grooving station 118 and other components according to the various aspects described herein for manufacture of the tubes 199. In one aspect, the software may be a PC implementing the program language DOT NET Datapack10. In one aspect, the PLC program language may be Rockwell RS Logix. The software may also include instructions to control the entire milling process including the components described in
The memory 704 may also include the database 708, which may include information about various types of coils used in the milling process including specifications such as length, material of the coils, indicators used on the coils and the like, and the tube which are formed from the coils such as diameter, length, and the like. The database 708 may store various regulations of the United States and other countries such as Canada, Mexico, Brazil, China and the like that are related to the sample testing of the coils such as when to cut the sample and length of the sample. The database 708 may also include other information for use with other components of the grooving station 118 such as information regarding various wireless protocols for the wired/wireless interface 714, and information regarding various indicators that are used in and outside of the U.S. and the like.
The display 710 may be integral with the grooving station 118 or be remote therefrom including in a remote location. The display can be any type of display including TIFF, LED, OLED, Plasma, SVGA, VGA and the like and can include a touch screen surface to interact with the user. The display 710 may communicate via a wired or wireless connection with the processor 702 so that the processor 702 may receive the user's input.
The sensors 712 may be any type of sensor including position, velocity, acoustic, chemical, visual and the like. The sensors 712 may be integral with the grooving station 118 or be remotely positioned to detect the tube 199 as it is being milled. For example, the sensor 712 may be a camera such as a CCD camera, and the like. An image of the tube 199 may be captured by the camera and then compared to images in the database in order to confirm what further actions need to be taken and when. The sensors 712 may communicate with the processor 702, the memory 704, the software 706, the database 708, and the like via a wired or wireless connection. In one aspect, the sensors 712 may include a position/velocity sensor. The position/velocity sensor may be one or more of a capacitive transducer, capacitive displacement sensor, eddy-current sensor, grating sensor, hall effect sensor, inductive non-contact position sensors, linear variable differential transformer (LVDT), multi-axis displacement transducer, photodiode array, piezo-electric transducer (piezo-electric), potentiometer, proximity sensor (optical), rotary encoder (angular), string potentiometer, or the like.
The wired/wireless interface 714 allows for wireless communication with the components of the grooving station 118, other remote computing devices or the components in the milling process (of
In particular,
As illustrated in box 1404, a second conveyor receives the one of the plurality of tubes 199 from the first conveyor and delivers a plurality of the tubes to a third conveyor. The second conveyor may be the stepper conveyor 208. As illustrated in box 1406, the third conveyor receives the plurality of tubes 199 from the second conveyor and delivers the plurality the tubes to a fourth conveyor. The third conveyor may be the chain conveyor 210.
As illustrated in box 1408, the fourth conveyor receives the plurality of tubes from the third conveyor and conveys the plurality of tubes to the first groove forming machine 200. The fourth conveyor may be the drive rollers 220. As illustrated in box 1410, a first groove is formed on one end of a plurality of tubes with a first groove forming machine 200.
As illustrated in box 1412, a fifth conveyor receives the plurality of tubes 199 and aligns the plurality of tubes 199 for a subsequent grooving process. The fifth conveyor may be the conveyor rollers 212. In this regard, 1412 helps ensure that the tubes 199 receive the groove at the appropriate location on the tubes 199. As illustrated in box 1414, a sixth conveyor receives the plurality of tubes from the third conveyor and conveys the plurality of tubes to the second groove forming machine 200. The sixth conveyor may be the drive rollers 222.
As illustrated in box 1416, a second groove is formed on another end of the plurality of tubes 199 with the second groove forming machine 200.
In particular,
Accordingly, the disclosure has set forth an automated system and process to form grooves on ends of tubes 199 with increased speed as well as improved quality. In particular, implementing a groove forming machine 200 configured to form grooves on a plurality of tubes 199 simultaneously increases speed. Moreover, implementing a groove forming machine 200 at each end of the tube 199 further increases speed. Additionally, the various alignment processes and disclosed devices and processes result in improved quality. In particular, the disclosed combination of conveyors, controller, sensors, and alignment processes help ensure that the tube 199 receives the groove at the appropriate location on the tube 199.
Aspects of the disclosure may include a server executing an instance of an application or software configured to accept requests from a client and giving responses accordingly. The server may run on any computer including dedicated computers. The computer may include at least one processing element, typically a central processing unit (CPU), and some form of memory. The processing element may carry out arithmetic and logic operations, and a sequencing and control unit may change the order of operations in response to stored information. The server may include peripheral devices that may allow information to be retrieved from an external source, and the result of operations saved and retrieved. The server may operate within a client-server architecture. The server may perform some tasks on behalf of clients. The clients may connect to the server through the network on a communication channel as defined herein. The server may use memory with error detection and correction, redundant disks, redundant power supplies and so on.
Relative terms such as “below” or “above” or “upper” or “lower” or “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures.
The many features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the disclosure which fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure.
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Number | Date | Country |
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2522528 | Nov 2012 | EP |
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Number | Date | Country | |
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20200147664 A1 | May 2020 | US |