Method and system for forming tubular or truncated cone segments

Abstract

1. A method for forming a tubular segment, comprising pressing one or a series of metal strips into a tubular or frusto-conical shape such that opposing longitudinal ends of the one or a series of metal strips meet to form at least one seam, thereafter welding the seam to join the joined ends, at least after welding, a cross-sectional shape of at least a portion of the segment is measured at least at and / or near the welded seam, data of the measurements is provided to a controller, and then a press is operated by the controller based on the data to adjust the cross-sectional shape of the segment at least at the seam.

Description

[Technical Field]

[0001] The present invention relates to a method for forming tubular segments. The present invention further relates to a pressing system for forming tubular or cut-off cone-shaped metal segments. [Background technology]

[0002] Tubular segments and truncated cone segments are known in the art and are commonly used, for example, to form foundation piles for onshore or offshore structures such as large tanks, silos, wind turbine towers, and wind power generators.

[0003] Such tubular segments can have a diameter of several meters and are generally formed by press-forming metal strips up to several centimeters thick into such segments using a press, particularly a roller press, or by forming multiple segment sections and joining them together. One or more of these metal strips are press-formed into a tubular or hollow truncated cone shape or a portion thereof. In the process, the opposing longitudinal ends of one or more strips come together to form one or more joints. These joints are welded, and the joined ends are joined together.

[0004] In various applications, it is highly desirable, or even specified, that the cross-sectional shape of one end of a segment, or both opposing ends of a segment, be within a predetermined range, such as a predefined minimum and maximum radius. When segments are welded together, deformation occurs, at least at and near the joint, due to heating and cooling, material addition, etc., which almost inevitably affects the segment's cross-sectional shape. This causes at least a portion of the cross-sectional shape to deviate from the set limits, for example, by going too far inward or outward. Therefore, after welding, the cross-sectional shape of at least a portion of the segment is measured at least at and / or near the welded joint, and the cross-sectional shape is evaluated against the set limits. This allows the operator to feed the segment back into the press to adjust the cross-sectional shape after welding using a press.

[0005] In this technical field, a template representing a portion of the desired cross-sectional shape is used to evaluate the cross-sectional shape of a segment. The template is pressed against the outer or inner surface of the segment by an operator, who visually inspects for any gaps between the template and the pressed surface. Based on experience, the operator returns the segment to the press, identifies the evaluated portion of the segment within the press, and adjusts the cross-sectional shape of the segment by operating the press to bring the corresponding portion of the segment's cross-sectional shape within a set range. [Overview of the project]

[0006] This known method is cumbersome and prone to errors. Operators may misposition the template, misjudge the difference between the template and the actual measurement surface, or misconfigure the press machine settings and controls. Furthermore, the effectiveness of this method depends heavily on the operator's experience.

[0007] The object of the present disclosure is to provide an alternative method for forming a tubular or frustoconical segment. The object of the present disclosure is to provide a method that can better control the forming process. The object of the present disclosure is to provide a more efficient and effective method for forming a tubular or frustoconical segment. The object of the present disclosure is to provide a method for forming a tubular or frustoconical segment that can improve efficiency over time. The object of the present disclosure is to provide a press system for forming a tubular or frustoconical segment, and to manufacture such a segment in an easier and more controllable manner.

[0008] At least one of these objects can be achieved, at least in part, by the method or press system according to the present disclosure.

[0009] In one aspect, the method according to the present disclosure includes steps for forming a tubular segment, pressing one or a series of metal strips into a tubular or frustoconical shape such that the opposing longitudinal ends of the one or series of metal strips meet to form at least one seam, and then welding the seam to join the mated ends. At least after welding, the cross-sectional shape of at least a part of the segment is measured at least at the welded seam and / or in its vicinity. The data of this measurement is supplied to a control unit, and then based on this data, the control unit operates the press to adjust the cross-sectional shape of the tubular segment at each of at least one or a plurality of seams.

[0010] In the method according to the present disclosure, the control unit can accurately control and thus operate the press for modifying the cross-sectional shape at an appropriate position in order to bring the cross-sectional shape closer to or within the desired shape. The method according to the present disclosure makes it possible to more easily and accurately form a segment having a desired configuration.

[0011] In one aspect of the method according to the present disclosure, the cross-sectional shape of the segment is measured using a measuring tool, and the measurement data obtained using the measuring tool includes at least the position data of the corresponding portion of the cross-sectional shape measured with respect to the tool and the distance between the portion of the cross-sectional shape and the measuring tool.

[0012] By such a method, the segment can be positioned more easily and accurately within the press in order to adjust the cross-sectional shape at an accurate position. For example, the position of the measured portion of the segment is defined relative to the press, and by rotating the roll of the press, for example, the corresponding portion of the segment can be easily introduced into the press at the correct position.

[0013] In an embodiment of the method according to the present disclosure, the metal strip is rolled or formed into a segment having a circular or semi-circular cross-section at least at one end, the desired radius of which is set between the set minimum radius and the set maximum radius in the control unit. After welding, the actual radius is measured at least at the joint, and the actual radius is compared with the set desired radius. Then, the press is operated by the control unit to reduce the deviation between the actual radius and the desired radius.

[0014] In such an embodiment, a segment having a substantially circular cross-section is formed, and this segment needs to have a substantially constant desired radius measured, for example, on the inner or outer surface of the segment at least at one end. The desired radius must be within the set minimum and maximum limits, for example, to meet legal requirements or customer requirements and to be compatible with the segments connected to it at the longitudinal ends. In an embodiment of the method of the present disclosure, the press is operated by the control unit such that the actual radius is between the set minimum radius and the set maximum radius.

[0015] In embodiments of the present disclosure, one or more roller presses are used. In embodiments, at least two presses are used, one for pre-pressing the strip or for roughly shaping it into the desired tubular or cut shape, and a second for adjusting the cross-sectional shape of the tubular segment after welding. The first and second presses may be the same press, but preferably the first press is different from the second press. For example, the first press may be a four-roll press and the second press may be a three-roll press.

[0016] In one embodiment, the method according to the present disclosure is characterized by the use of a roller press having at least three rolls to adjust the cross-sectional shape of the joint after welding, wherein the segment is supported on both sides of the joint by two rolls on the outer surface of the segment, and at least a third roll of the at least three rolls is pressed against the inner surface of the segment toward the two outer rolls at or near the joint, and the force for the pressing, and / or the distance the third roll travels toward the two outer rolls, is controlled by the control unit based on the measurement data.

[0017] By using at least three rolls, the segment can be easily and accurately supported on its outer surface, while at least one additional roll can be used to press the segment against the two support rolls, viewed radially, between the two support rolls, and the measurement data can be used for the precise movement and / or force of the additional roll. This makes it possible to precisely adjust the relevant portion of the segment to bring the cross-sectional shape within the specifications set for that cross-sectional shape. In embodiments, it is obvious that if the cross-sectional shape of the segment is oriented outward, a press can be used in which a portion of the cross-sectional shape is pressed inward, i.e., toward the centerline of the segment.

[0018] The method described herein can be used with non-contact measuring tools. For example, optical measuring systems such as laser measuring systems or digital cameras can be used. Alternatively, mechanical measuring systems such as digital measuring clocks or dial gauge measuring systems, or a combination of non-contact and contact measuring systems can be used.

[0019] The methods according to the present disclosure may be used in particular to form, for example, foundation piles or tower segments of wind turbines or offshore structures. More generally, the methods according to the present disclosure can be used to form relatively large diameter segments for elongated hollow structures to which narrow tolerances in cross-sectional shape are applied, for example, tubular segments with a wall thickness of several centimeters, e.g., between 1 and 10 cm, e.g., between 3 and 6 cm; tubular segments with a cross-sectional diameter of several meters, e.g., 5 m or more at the maximum cross-section, e.g., 6 m or more, or 8 m or more; and tubular segments with a diameter tolerance of only a few millimeters, e.g., less than 10 mm, e.g., less than 7 mm, e.g., less than 4 mm.

[0020] In one embodiment, a press system for forming a tubular or truncated cone metal segment according to the present disclosure features at least a press and a control unit for controlling the press, the system further comprising a measuring tool for measuring at least a portion of the cross-sectional shape of the tubular or truncated cone segment, the measuring tool being connected to the control unit to supply the measuring data to the control unit, the control unit comprising at least an algorithm for controlling the press based at least the measuring data.

[0021] The measuring tool electronically provides measurement data, such as digital data, to the control unit, which can then use the press machine's control unit to control the press machine.

[0022] In some embodiments, the measuring tool may be a non-contact measuring tool, such as an optical measuring tool. In some embodiments, the measuring tool includes at least a laser measuring system.

[0023] In embodiments, the press system, particularly the control unit, includes a memory containing at least a predefined desired radius of the segment to be formed, the control unit and the measuring tool are designed to acquire and process measurement data including position data of a position in the segment and radius data at the position, and the control unit may further include an algorithm for comparing the radius at the position with the desired radius and controlling the press based on the comparison.

[0024] Such a system can store a set of data for one, several, or substantially all locations along the entire cross-section of a segment, consisting of data for the corresponding location relative to a measuring tool or press, and the distance between the measuring tool and the cross-sectional shape at that location. This data can be, for example, the radius of the segment at that location, or can be converted to a radius.

[0025] For example, in the case of a segment whose cross-section must be circular, the desired radius will be the same at all locations and can therefore be compared with the radius actually measured at that location. Based on such comparisons and positional data, the segment is moved within the press machine, bringing the relevant position into the press machine, i.e., between the rollers of a roller press or on the table of a bench press, and then the control unit operates the press machine to change the radius at the said position, bringing it closer to the set desired radius. If the cross-section is not circular, for example, oval or elliptical, it is obvious that the desired radius will differ depending on the location.

[0026] In embodiments, the press system of the present disclosure may include at least a first press for pre-pressing segments, a welding station for welding at least one joint in the segments, and a second press for re-pressing the formed segments after they have undergone the welding process at the welding station. Preferably, the first and second presses are different presses, for example, located near the beginning and end of a segment processing line, and the welding station may be located between the two presses.

[0027] In the embodiment, the control unit includes an algorithm for performing the steps of measuring at least a portion of the cross-sectional shape of a tubular or cut-off cone segment, and iteratively controlling the press machine during a segment pressing process based at least on the measurement data. The control unit may further be designed to use the measurement data from the pressing process for evaluating the control of the press machine during subsequent pressing processes.

[0028] In such embodiments, at least a portion of the cross-sectional shape of the segment can be adjusted in two or more consecutive adjustment steps, with at least one measurement step between these adjustment steps, so that the radius of that position can be brought closer to a desired radius in a series of steps.

[0029] The disclosure further relates to a computer program product including a computer-readable program for controlling a pressing process for forming tubular or truncated conical metal segments, the program being designed to receive measurement data relating to the cross-sectional shape of at least a portion of the segments and to control a press to adjust the cross-sectional shape.

[0030] To better understand this disclosure, embodiments of the methods, press systems, and computer program products described herein will be explained illustratively with reference to the drawings. [Brief explanation of the drawing]

[0031] [Figure 1] This is a schematic end view showing a metal strip being supplied to a press machine. [Figure 1A] This diagram schematically shows the state of a strip during feeding and pressing in a press machine. [Figure 2] Figure 1 is a schematic end view showing the process of forming a tubular segment from a strip using a press machine, and then joining the opposing ends of the strip to form a joint. [Figure 3] This is a schematic end view showing a tubular segment before welding at the joint. [Figure 4] This is a schematic end view showing a tubular segment inside a welding station. [Figure 5] This is a schematic end view showing a tubular segment after welding. [Figure 6] This is a schematic end view showing a tubular segment inside a press machine after welding. In the figure, at least a portion of the cross-sectional shape of the tubular segment is being measured. [Figure 7] This is a schematic end view showing a portion of the cross-sectional shape, including the welded joint. The figure shows deformation due to welding at least at the joint. [Figure 8] This is a schematic end view showing a segment with a portion whose cross-sectional shape has been deformed within the press machine. [Figure 9] This is a schematic end view showing the segment, particularly the cross-sectional shape after measurement and re-pressing. [Figure 10A] This is a schematic side view showing a tubular segment formed in accordance with this disclosure. [Figure 10B] This is a schematic side view showing a truncated cone-shaped segment formed in accordance with this disclosure. [Figure 11] This is a schematic diagram illustrating a press system for forming segments from a strip in accordance with this disclosure. [Modes for carrying out the invention]

[0032] The embodiments shown in the drawings and described below are illustrative only and should not be considered to limit the scope of this disclosure.

[0033] This disclosure describes a method and system for forming a metal strip into tubular or hollow truncated cone segments. Using this method and system, multi-segment hollow structures can be constructed by mounting two or more of the segments vertically, as is known in the art, for example, to form foundation piles or towers for wind turbines or offshore structures. In the illustrations and description of this disclosure, a metal strip is rolled to form a tubular segment having a circular cross-section, or a truncated cone segment having a circular cross-section in which the radius decreases from one longitudinal end of the segment to the other longitudinal end. However, segments with cross-sectional shapes other than circular, such as oval, elliptical, polygonal, etc., can also be formed.

[0034] In this specification, the cross-sectional shape of a segment should be understood as the shape of the segment as viewed in a plane perpendicular to the longitudinal axis of the segment. This is the cross-sectional shape formed by pressing a strip into the shape of a segment. A metal strip should be understood as a strip made of metal that can be deformed by a press machine such as a roller press or a brake press. The strip may be made of, for example, steel, aluminum, or a suitable metal alloy.

[0035] Figure 1 shows a strip 1 being fed into a press 3 to form segment 2, where the press 3 is shown as a roller press, particularly a four-roller press, as known in the art. Herein, as an example, the press 3 is shown to have two upper rolls 4 and two lower rolls 5. The strip 1 is positioned between the upper rolls 4 and the lower rolls 5 (also referred to as the inner rolls 4 and outer rolls 5), and when the upper rolls 4 are pressed down against the lower rolls 5, the portion of the strip between the rolls 4 and 5 is bent, for example, as shown in Figure 1A for a three-roll press. By moving the strip 1 through the press 3, the longitudinal ends 6 and 7 of the strip 1 are joined together, as shown in Figure 2, so that a joint 8 is formed at least by and / or between the longitudinal ends 6 and 7. Thus, a substantially tubular segment 2 is formed.

[0036] Each drawing shows a segment 2 formed from a single strip 1. In these examples, the longitudinal length L of strip 1 is equal to the circumference of the segment, following the equation L = 2πR (where R is the average radius of the cross-section of the tubular segment 2). However, it is also possible to form a segment from two or more segment portions, in which case each segment portion is press-formed from a strip having a smaller length, and each segment portion forms part of the outer perimeter of the segment, i.e., part of the outer wall 9 of segment 2. For example, two semicircular segment portions can be formed and welded together to form segment 2, and two seams 8 can be formed in this segment 2. Similarly, segment 2 can be formed by welding together three or more segment portions, thereby forming the same number of seams 8 as the number of segment portions.

[0037] For example, as shown in Figures 2 and 3, the longitudinal ends 6, 7 of one or more strips may be machined to form, for example, a cross-sectional shape 10 that emphasizes the seam. In the illustrated embodiment, the cross-sectional shape 10 that emphasizes the seam is formed by chamfering the ends 6, 7 so that a substantially V-shaped groove 11 is formed in the seam 8 in the formed segment 2. In the illustrated embodiment, the groove 11 opens toward the longitudinal axis 12 of the segment 2. After forming the segment 2, or at least the seam 8, the ends 6, 7 can be tack welded in known ways to bring them into close contact while the segment is being further handled until at least the seam 8 is properly seam welded. This will be discussed later.

[0038] After forming the segment 2 in the segment forming station 30, the segment can be removed from the press machine 3, as shown in Figure 3, and transported to the welding station 13, for example, as shown in Figure 11. However, welding can also be performed while the segment 2 is held by the press 3.

[0039] Figure 4 shows an example where segment 2 is inside the welding station 13 and the seam 8 is on the underside. In the welding station 13, using a welding tool 15 in a known manner, a seam weld 14 is formed inside and / or on the seam 8, and both ends 6, 7 of the strip 1 are welded. This may be an automated process, a manual process, or a combination of both.

[0040] As shown in Figures 5 and 7, for example, the seam 8 and the portion 16 of the cross-sectional shape P in its vicinity, or at least the seam weld 14, are deformed by heating and cooling of the portion of the segment 2, for example. In the drawings, the distortion 17 may be exaggerated to make it more clearly visible. In the embodiment, the distortion 17 is shown as inward distortion 17. This is distortion in the direction of the longitudinal axis 12 of the segment 2. Preferably, the configuration of the cross-sectional shape 10 that emphasizes the seam is selected so that the distortion is inward. Such a configuration is also called "apple-shaped". This has been shown to be easier to correct than outward distortion 17. However, outward distortion can also occur, which is called "pear-shaped".

[0041] The occurrence of strain 17 in the cross-sectional shape P of segment 2 is undesirable, at least when properly connecting segment 2 to another adjacent segment 2, for example, when constructing towers, piles, silos, or tanks. For example, segment 2 will not fit correctly vertically due to the strain. Furthermore, such strain can impair the strength of the segment and the strength of the structure using such a segment. Moreover, such strain can impair the shape and appearance of the segment.

[0042] Accordingly, in the method of the present disclosure, as shown in Figure 6, the segment 2 can be placed in the press system 18 of the present disclosure after welding, which includes at least a press machine 3, 20 and a control unit 19 for controlling the press machine. For example, in the embodiments shown in Figures 6, 8 and 11, the press machine is a roller press, in particular a three-roll press 20, which is a different press machine from the press machine 3 used to pre-roll the strip 1 into a segment 2 having a substantially circular cross-section before welding, as shown in Figures 1 and 2, for example. However, the press machine in the press system 18 may be the same press machine 3.

[0043] For example, as shown in Figure 8, the press system 18 further comprises a measuring tool 21 for measuring at least a portion of the cross-sectional shape P of a tubular or cut-off cone segment 2, and this measuring tool 21 is connected to the control unit 19 to supply the measuring data D to the control unit 19. The control unit 19 includes at least an algorithm for controlling the press machines 3,20 based at least the measuring data D.

[0044] The measuring tool 21 is preferably a non-contact measuring system based on, or including, a laser measuring system 22. The laser measuring system 22 measures the actual radius R A The measurement can be taken at any position along the inner circumference of the segment extending around the measuring tool 21. For example, in the embodiment shown in Figure 6, the measuring tool 21 is positioned facing straight upward on or near the longitudinal axis 12 of the segment 2, and the longitudinal axis 12 and the vertical plane P extending through the longitudinal axis 12 v Between the measurement point or measurement position T directly above the measuring tool 21, the radius R A It is now possible to measure the above plane P directly. v The line is perpendicular to the drawing. In Figure 6, the measurement position T is the innermost part of the seam weld 14. The actual radius R at the above measurement position or measurement point T. A By measuring this, the cross-sectional shape P can be evaluated.

[0045] For example, in the illustrated embodiment, the segment is rotated around the longitudinal axis 12, and a sequence of measurement positions T can be obtained, for example, in discrete steps or a continuous process, and for each measurement position T, the relative position of that position and the actual radius R can be obtained. A This is registered as data. In this way, a more accurate cross-sectional shape P can be obtained for the relevant portion 16 of the cross-section, in this case the area around the joints 8 and 14.

[0046] The measuring tool 21 measures the actual radius R. ASo that it can be calculated from the measurement data obtained by the measurement tool 21, for example, as long as the position with respect to the longitudinal axis 12 is known, it can also be arranged at different positions, for example, at an interval from the longitudinal axis. The measurement tool 21 can alternatively be arranged outside the segment 2, for example, in contact with the outer surface 27 or at an interval from the outer surface 27.

[0047] The actual radius R at a certain position T A is the desired radius R at that position D and can be compared. Based on such a comparison, the press machines 3, 20 can be used to change the cross-sectional shape P to approach the desired shape. In the tubular or conical segment 2, the desired radius R D should be substantially the same or at least the same for all positions T within the cross-section. The purpose of the method of the present disclosure is to make R A sufficiently close to the desired radius R D Therefore, the measurement data D is supplied to the control unit 19, and then, based on the data, the control unit 19 operates the press machines 3, 20, whereby the cross-sectional shape P of the tubular segment 2 is adjusted at each of at least one or a plurality of joints 8.

[0048] In an embodiment, the cross-sectional shape P of the corresponding portion 16 of the segment 2 is measured using the measurement tool 21, and the measurement data D obtained by the measurement tool includes at least the position data D of the corresponding portion of the cross-sectional shape measured with respect to the tool 21 and the distance between the above-mentioned portion of the cross-sectional shape and the tool 21, that is, the actual radius R A or the measurement value representing the actual radius R A is included.

[0049] In an embodiment, the control unit 19 can include a memory 23 including at least a predefined desired radius R of the segment 2 to be formed, and the control unit 19 and the measurement tool 21 are configured to obtain the position data of the position T in the segment 2 and the radius data R at that position D and the radius data R at that position AThe control unit 19 is designed to acquire and process measurement data D including the radius R at position T. A and the desired radius R D The system includes an algorithm for comparing the two and controlling the press machines 3 and 20 based on the comparison. For segments 2 having a circular cross-section, or segments having a semicircular or partially circular cross-section, the control unit 19 sets a minimum radius R min The maximum radius R is set as follows: max Between, a single desired radius R D It can be set. After welding, the actual radius R A This was measured at least at seams 8 and 14, and this actual radius R A The desired radius R is set. D It is then compared to the actual radius R. A and the desired radius R D To reduce the deviation between the actual radius and the minimum radius R, the control unit 19 operates the press machine 3 or 20. In the embodiment, the press machine 3 or 20 operates the actual radius as shown schematically in Figures 7 and 8, for example, to set the minimum radius R min The maximum radius R is set as follows: max The relevant part of the cross-sectional shape is pressed to force it into place between the two.

[0050] As mentioned above, the metal strip can be rolled into a tubular or cut-cone shape using a roller press 3, but this roller press 3 can be a different press from the press 20, for example, another roller press 20 or brake press used to adjust the cross-sectional shape P after welding of the joints 8, 14. By using different presses 3, 20 before and after welding, the advantage is obtained that the process of forming the tubular or cut-cone segments 2 can be carried out as a substantially continuous or semi-continuous process, and the segments 2 can move along the production line 24 from the first press 3 to the second press 20, and can pass at least from the forming station 30 through the welding station 13 to the re-pressing station 31, and there is no need to return the segments 2 back up the line 24 to the first press 3. This is shown, for example, in Figure 11. Furthermore, this allows for the selection of the optimal presses as the first press 3 and the second press 20. Alternatively, the metal strip 1 can be rolled into a tubular or cut-off cone shape using a roller press 3, which is the same press 3 used, for example, to adjust the cross-sectional shape P at the seams 8, 14 after welding.

[0051] In this embodiment, the control unit 19 includes an algorithm in a computer system 25 designed to control the press machines 3, 20 to adjust the cross-sectional shape P based on data D received from the measuring tool 21.

[0052] In an advantageous embodiment, a roller press 20 having at least three rolls 4, 5 is used to adjust the cross-sectional shape P at least at the welded joints 8, 14, wherein the segment 2 is supported by two rolls 5 on the outer surface 26 of the segment 2, and at least the third roll 4 of the rolls 4, 5 is pressed against the inner surface 27 of the segment 2 toward the two rolls 5 on the outer surface 26. The force F for the pressing and / or the distance D of the movement of the third roll 4 toward the two rolls 5 on the outer surface 26. tThis is controlled by the control unit 19 based on the aforementioned measurement data D. For example, to adjust the cross-sectional shape P of the seams 8 and 14, two rolls on the outer surface 26 can be placed on both sides of the seams 8 and 14, and a third roll 4 can be placed on the inner surface 27 at or near the seam.

[0053] By the same or similar methods and systems, for example, the evaluation of the entire cross-sectional shape of a segment, for example, the maximum outer radius R of this cross-section. max A circle defined by and with a set minimum radius R min It is clear that, in order to evaluate whether the cross-section fits perfectly within the circle defined by, i.e., the circularity of such a cross-section, the cross-sectional shape P at locations other than the seam can also be measured and evaluated.

[0054] As explained, the measuring tool 21 can be a non-contact measuring system or part thereof, such as a laser measuring system, more specifically a laser measuring system suitable for distance measurement. Alternatively, the measuring tool can consist of a camera and the actual radius R at position T. A To evaluate this, an algorithm can be used that evaluates images of the relevant portion of the cross-sectional shape P. Alternatively or additionally, a contact-type measuring tool, such as a digital measuring clock or a dial gauge measuring system, can be used, which can, for example, make contact with and travel along the inner surface 27 of the segment.

[0055] The control unit 19 preferably controls at least a predefined desired radius R of the segment 2 to be molded, as schematically shown in Figures 2 and 9. D The control unit 19 and measuring tool 21 are equipped with a memory 23 including the position data of position T in the segment 2 and measurement data D including radius data at position T, and the control unit 19 is designed to acquire and process measurement data D including the actual radius R at position T. A to the desired radius R DThe system further includes an algorithm for controlling the press machine 20 based on a comparison. The position data is a specific radius R relative to a known position in segment 2, particularly in the cross-sectional shape P. A (α) may include the rotation angle α of the measured position Tα. The known position is, for example, a marker provided on the seams 8, 14, or, for example, the inner surface 26 of segment 2. For example, in Figure 6, position T(α) is shown at an angle α with respect to the vertical line Z passing through seams 8, 14. Therefore, the radius R A From the point when (α) was measured at T(α), the measuring tool 21 in Figure 6 moves to a distance cq radius R. A With (α) measured directly upwards, the segment rotates clockwise around the longitudinal axis 12 by an angle α. Therefore, the position can be measured over 360 degrees or any angle.

[0056] The control unit 19 is preferably designed to perform the steps of measuring at least a portion of the cross-sectional shape P of the tubular or cut-off cone segment 2, and iteratively controlling the corresponding press machine 20 during the segment pressing process based at least the measurement data D. For example, immediately after welding the joint, the first measurement can be made by a measuring tool at, for example, the position T14 of the joints 8, 14, and during or after the measurement, the press machine 20 is operated by the control unit 19 as described above, and the measured actual radius R A at the desired set radius R of that position D Approach it. Then, radius R A The radius R is measured again at the above position T14. A The desired radius R D If you are not yet close enough, the radius R of position T14 A The desired radius R D To bring it closer, the press machine 20 is operated again. A and R D These steps can be repeated as long as the deviation is still too large.

[0057] Preferably, the press machine 20 is operated using a computer program product which includes a computer-readable program for controlling the pressing process for forming tubular or cut-cone shaped metal segments 2, the program being designed to receive measurement data D related to the cross-sectional shape P of at least a portion of the segment 2 and to control the press machine 20 to adjust the cross-sectional shape P.

[0058] In this disclosure, the tubular segment 2 has a longitudinal length L, as shown in Figure 10A, for example. s It should be understood that this means at least a tubular element having a substantially constant cross-section over a certain length. In this disclosure, the truncated conical segment 2 has a longitudinal length L, for example, as shown in Figure 10B. s It should be understood that this means at least a hollow element having a substantially uniform and similar shape, but increasing or decreasing cross-section. However, the segments according to this disclosure may have different shapes. For example, the cross-section may be polygonal in the plane perpendicular to the longitudinal axis 12, or it may be barrel-shaped, for example, i.e., in the longitudinal direction starting from a first end, the size of the cross-section initially increases and then decreases toward the opposite end.

[0059] The pressing system and method described herein can be used to form particularly large segments for use as foundation piles or tower segments for wind turbines or offshore structures. Such segments 2 may have, for example, a maximum diameter D(2*R) of 3 to 20 m and a length L of, for example, 2 to 6 m. s The segment can be cylindrical or truncated cone in shape. For example, such a segment can be formed from a steel strip 1 having a thickness S of 1 to 10 cm, for example, 1 to 6 cm. In the case of the segment according to this disclosure, the set radius R D Radius R A The deviation may be as small as a few millimeters, for example, 4 mm or less. Similarly, the deviation between the radii of adjacent segments should be as small as 10 mm or less, for example, 4 mm or less.

[0060] In the methods or press systems according to this disclosure, known presses 3, 20, such as those manufactured by Davi of Italy or Haeusler of Germany, can be used. For example, the segment 2 used in a generator tower is sometimes called a can.

[0061] This disclosure is not limited to the embodiments shown and described herein for illustrative purposes only. Many modifications are possible within the scope of this disclosure as defined by the claims.

[0062] For example, the measuring tool may be a camera or comprise a camera that can capture images from the longitudinal end of the segment, such as an optical image of a portion 16 of the segment's cross-sectional shape at or near the joint 8, and this image can be compared with a saved image of the desired segment. The deviation between these images can be used to control the press machines 3, 20 to bring the cross-sectional shape within an acceptable range. In this invention, other types of press machines can be used instead of a roller press to form and / or deform the segments.

[0063] These and other variations are considered to be within the scope of the present disclosure and within the scope of the present invention as defined by the appended claims.

Claims

1. A method for forming a tubular segment, comprising: pressing one or a series of metal strips into a tubular or truncated cone shape such that the opposing longitudinal ends of the one or a series of metal strips meet to form at least one joint; then welding the joint to join the joined ends; the longitudinal ends being machined to form a cross-sectional shape that emphasizes the joint, the cross-sectional shape being selected such that the joint deforms inward during welding; at least after welding, the cross-sectional shape of at least a portion of the segment being measured at least at the welded joint and / or near the welded joint; the measurement data being supplied to a control unit; then, based on the data, the control unit operating a press machine to adjust the cross-sectional shape of the segment at least at the joint; and a roller press being used to adjust the cross-sectional shape of the segment.

2. The method according to claim 1, wherein the cross-sectional shape of the portion of the segment is measured using a measuring tool, and the measurement data obtained using the measuring tool includes at least the position data of the portion of the cross-sectional shape measured relative to the tool, and the distance between the portion of the cross-sectional shape and the tool.

3. The method according to claim 1 or 2, wherein the metal strip is rolled or formed into segments having a circular or semicircular cross-section at at least one end, the radius of which is set in the control unit between a minimum radius and a maximum radius, and after welding, the actual radius is measured at least at the joint, the actual radius is compared with the set desired radius, and the press is then operated by the control unit to reduce the deviation between the actual radius and the desired radius.

4. The method according to claim 3, wherein the control unit operates the press machine so that the actual radius is between the set minimum radius and the set maximum radius.

5. The method according to any one of claims 1 to 4, wherein the metal strip is rolled into a tubular or cut-off cone shape using a roller press, and the roller press is a different press from the roller press used to adjust the cross-sectional shape after welding.

6. The method according to any one of claims 1 to 4, wherein the metal strip is rolled into a tubular or beveled cone shape using a roller press, the roller press being the same press used to adjust the cross-sectional shape at the joint after welding.

7. The method according to any one of claims 1 to 6, wherein the control unit comprises an algorithm for controlling the press machine to adjust the cross-sectional shape at least at the joint.

8. The method according to any one of claims 1 to 7, wherein a roller press having at least three rolls is used to adjust the cross-sectional shape of the joint after welding, the segment is supported on both sides of the joint by two rolls on the outer surface of the segment, at least a third roll of the at least three rolls is pressed against the inner surface of the segment toward the two outer rolls at or near the joint, and the force for the pressing, and / or the distance the third roll travels toward the two outer rolls is controlled by the control unit based on the measurement data.

9. The method according to any one of claims 1 to 8, wherein the cross-sectional shape is measured using at least a laser system.

10. The method according to any one of claims 1 to 9, wherein the segment is formed as a foundation pile or tower segment for a wind turbine or offshore structure.

11. A press system for forming a tubular or truncated cone metal segment, for carrying out the method of any one of claims 1 to 10, comprising at least a press machine and a control unit for controlling the press machine, the system further comprising a measuring tool for measuring at least a portion of the cross-sectional shape of the tubular or truncated cone segment, the measuring tool being connected to the control unit to supply the measuring data to the control unit, the control unit comprising at least an algorithm for controlling the press machine based at least the measuring data, the press machine being a roller press.

12. The press system according to claim 11, wherein the measuring tool includes a non-contact measuring system.

13. The press system according to claim 11 or 12, wherein the measuring tool includes a laser measuring system.

14. The press system according to any one of claims 11 to 13, wherein the control unit comprises a memory containing at least a predefined desired radius of a segment to be formed, the control unit and the measuring tool are designed to acquire and process measurement data including position data of a position in the segment and radius data at the position, and the control unit further comprises an algorithm for comparing the radius at the position with the desired radius and controlling the press based on the comparison.

15. The press system according to any one of claims 11 to 14, further comprising at least a first press for pre-pressing a segment, a welding station for welding at least one joint in the segment, and a second press for re-pressing the formed segment after it has undergone a welding process at the welding station.

16. The press system according to any one of claims 11 to 15, wherein the control unit comprises an algorithm for performing the steps of measuring at least a portion of the cross-sectional shape of the tubular or cut-off cone-shaped segment and iteratively controlling the press machine during the segment pressing process based at least on the measurement data.

17. The press system according to claim 16, wherein the control unit is designed to use the measurement data of the press process for evaluating the control of the press machine during subsequent press processes, based on the difference between the measured cross-sectional shape and a desired cross-sectional shape set in the control unit.

18. A computer program product comprising a computer-readable program for controlling a pressing process for forming a tubular or beveled cone-shaped metal segment in a pressing system according to any one of claims 1 to 10 or any one of claims 11 to 17, wherein the program is designed to receive measurement data relating to the cross-sectional shape of at least a portion of the segment and to control a roller press to adjust the cross-sectional shape.

19. The computer program product according to claim 18, wherein the program is designed to control the relative positions of the rolls of a roller press.

20. The method according to any one of claims 1 to 10, wherein at least two presses are used, one for pre-pressing the strip or for roughly shaping it into a desired tubular or cut shape, and the second for adjusting the cross-sectional shape of the tubular segment after welding.

21. The method according to claim 16 or 17, wherein at least a portion of the cross-sectional shape of the segment is adjusted by two or more consecutive adjustment steps, with at least one measuring step between the adjustment steps, the radius is measured at at least one position in the cross section, and the radius at that position is brought closer to a desired radius in a series of steps.

22. The method according to any one of claims 1 to 10, 20, or 21, wherein the segment is assembled from at least two metal strips.

23. The press system according to any one of claims 11 to 17, comprising at least a first press for pre-pressing a segment, a welding station for welding at least one joint in the segment, and a second press for re-pressing the formed segment after it has undergone a welding process at the welding station.

24. The press system according to claim 23, wherein the first press and the second press are different presses, located near the start and end of the segment processing line, and the welding station is located between the two presses.

25. The press system according to claim 23 or 24, wherein the first press machine has at least four rolls and the second press machine has at least three rolls.

26. The press system according to claim 25, wherein the first press machine has four press rolls and the second press machine has three press rolls.

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