A small-angle elbow blanking layout device and a blanking layout method

Abstract

The application provides a small-angle elbow unloading lofting device, characterized in that the device comprises a body, the body comprises a lofting part and an auxiliary measuring part; the lofting part comprises a sector structure with a central angle of 90 DEG, reference scale lines are printed on two edges of the sector structure, a plurality of reference lines with angle scales are arranged on the sector structure, and each reference line has a center at the vertex of the sector structure; the front surface and the back surface of the auxiliary measuring part are printed with an unloading lofting quick-check table, and a measuring scale mark is arranged on the surface of the body corresponding to each edge of the auxiliary measuring part. The sector lofting module, the multi-standard scale and the quick-check table are highly integrated, the tool integration and the operation standardization are realized, the precision and the efficiency of on-site lofting are improved, the cumulative error and the uneven problem of alignment are effectively eliminated, the dependence on personnel experience and external conditions is reduced, and the device is especially suitable for rapid and high-quality construction under harsh working conditions.

Description

Technical Field

[0001] This invention belongs to the field of pipeline engineering construction technology, and in particular relates to a small-angle elbow material laying out device and material laying out method. Background Technology

[0002] In pipeline construction, especially in the petroleum, chemical, power, and municipal sectors, it is often necessary to fabricate elbows at specific angles based on actual site conditions to achieve pipeline turning connections. For small-angle elbows (typically 1° to 10°), due to their minute angles, using standard prefabricated elbows is often costly, has long delivery cycles, and is difficult to accurately match the complex installation dimensions on site. Therefore, on-site fabrication of small-angle elbows has become the most common and economical solution. However, traditional on-site elbow layout and cutting methods, such as the steel tape measure circumference marking method and the simple equal-diameter pipe division method, have significant inherent drawbacks, including: 1. Low precision: Traditional methods are prone to cumulative errors in the process of dividing points and lines on the circumference of the pipe wall, resulting in irregular horseshoe-shaped ends and problems such as inconsistent gaps and severe misalignment when pipe ends are joined. 2. Low efficiency: Relying on the personal experience and spatial imagination of construction workers, the operation process is cumbersome and complex, and the layout time is long. More seriously, the pipe end correction work (commonly known as "end trimming") caused by accuracy issues is time-consuming and labor-intensive, which seriously slows down the construction progress; 3. Unstable quality: The layout results are greatly affected by human factors, making standardization difficult. The quality of elbows produced by different personnel or at different times varies, posing a potential threat to the long-term safe operation of the pipeline system. 4. Reliance on specific tools: It usually requires the use of computer-aided design (CAD) software for accurate calculations and point layout, which is often difficult to achieve on a construction site with limited resources. Summary of the Invention

[0003] In view of this, the present invention aims to overcome the defects in the prior art and proposes a small-angle elbow material layout tool and material layout method. By highly integrating the fan-shaped layout module, multi-standard scale, and quick reference table covering a wide range of pipe diameters and bending radii, the invention achieves tool integration and standardized operation, improves the accuracy and efficiency of on-site layout, effectively eliminates the problems of cumulative errors and uneven alignment, and reduces the dependence on personnel experience and external conditions. It is especially suitable for rapid and high-quality construction under harsh working conditions.

[0004] To achieve the above objectives, the technical solution created by this invention is implemented as follows: A small-angle elbow blanking and layout device includes a main body, which includes a layout part and an auxiliary measurement part. The layout part is printed with reference scale lines and has several reference lines with angle scales on a fan-shaped structure. The front and back of the auxiliary measurement part are printed with a blanking and layout quick reference table, and the main body surface is marked with a measuring scale corresponding to each side of the auxiliary measurement part.

[0005] Furthermore, the measuring scale markings include imperial scale markings and at least one metric scale marking.

[0006] Furthermore, the measuring scale markings also include scale markings.

[0007] Furthermore, the scale markings and the imperial scale markings are located on the same side surface of the body.

[0008] Furthermore, the surface of the main body that is different from the imperial scale markings has two sets of metric scale markings, with the zero mark lines of these two sets of metric scales coinciding and sharing the same origin.

[0009] Furthermore, the reference lines include 0° reference line, 15° reference line, 30° reference line, 45° reference line, 60° reference line, 75° reference line and 90° reference line.

[0010] Furthermore, the quick reference table for material layout includes a quick reference table for the layout method of dividing the pipe circumference into 12 equal parts when the bending radius is 1 times the pipe diameter, a quick reference table for the layout method of dividing the pipe circumference into 12 equal parts when the bending radius is 1.5 times the pipe diameter, and a quick reference table for commonly used data.

[0011] Furthermore, the quick reference table for material layout covers a pipe diameter range of 600mm to 3200mm.

[0012] A method for laying out small-angle elbows using the above-mentioned layout device includes the following steps: S1. Check the outer diameter of the pipe and calculate the maximum cutting surface. The maximum cutting surface A = tg elbow angle * pipe inner diameter. S2. Take the value of the layout, the layout value R = ½A; S3. Draw an arc with the vertex of the fan-shaped structure as the center and the lofting value R as the radius, and mark the intersection of the arc with each baseline. S4. Measure the vertical distance from each intersection point to the origin of the reference scale line; S5. Measure the circumference L of the inner wall of the pipe end; S6. Based on the circumference L, divide the pipe circumference into 24 equal parts. The axial length of each segment is taken as an integer that is close to and greater than the maximum cutting surface A. The segments at the four positions of "0 point", "3 point", "6 point" and "9 point" are lengthened to 1.5A and marked. S7. Mark the cutting points on the 24 lines along the circumference of the pipe, starting from "0 point", based on the values ​​measured in step S5. S8. Connect the cutting points to form a cutting line; S9. After cutting along the cutting line to form a horseshoe-shaped opening, connect the flush end of the pipe to the horseshoe-shaped opening to complete the elbow fabrication.

[0013] Compared with existing technologies, the present invention has the following advantages: The layout tool provided by this invention includes a main body, which is divided into a layout section and an auxiliary measurement section. The layout section has a 90° sector-shaped structure, with reference scale lines and multiple reference lines with angle scales centered at the apex of the sector. The auxiliary measurement section has a quick reference table and commonly used data printed on both sides, covering pipe diameters of DN600-DN3200 and bending radii of 1.0D and 1.5D, for the 12-part ½-pipe circumference layout method. Each edge has imperial and metric scales and a scale. In application, the layout value R is determined by calculating the maximum cutting surface, and the layout tool is used to quickly obtain the cutting point data. Combined with the equal division of the pipe circumference, accurate marking is achieved. This invention integrates multiple functions, effectively solving the problems of large errors and low efficiency of traditional methods, significantly improving the accuracy and construction efficiency of on-site fabrication of small-angle elbows, reducing the end-cutting time, and is suitable for on-site elbow fabrication of steel pipes. Attached Figure Description

[0014] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 A frontal structural diagram of the invention; Figure 2 A schematic diagram of the back structure created for this invention; Figure 3 This is a schematic diagram of the lofting section in this invention. Figure 4 A schematic diagram illustrating the steps for marking the intersection points of the arc with each baseline; Figure 5 A schematic diagram illustrating the steps for measuring the perpendicular distance between each intersection point and the edge of the sector structure; Figure 6 A schematic diagram illustrating the steps of dividing the circumference of a pipe into 24 parts and marking them. Figure 7 This is a schematic diagram illustrating the steps of connecting the various dividing points into dividing lines. Figure 8 A schematic diagram illustrating the steps of creating cutting points by placing points along 12 lines; Figure 9 This is a schematic diagram illustrating the steps of connecting the cutting points into a cutting line. Figure 10 This is a schematic diagram of a pipe after it has been cut into a horseshoe shape along the cutting line. Detailed Implementation

[0015] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0016] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0017] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0018] The invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0019] A small-angle elbow feeding and distribution device, such as Figures 1 to 3 As shown, the device includes a main body, which includes a layout section 1 and an auxiliary measurement section 2. The layout section includes a fan-shaped structure with a central angle of 90°. The front and back of the layout section have the same structure, and the layout section has reference scale lines 4 printed on the two sides 3 of the fan-shaped structure. Several reference lines 7 with angle scales are provided on the fan-shaped structure, and each reference line is centered at the vertex of the fan-shaped structure. The front and back of the auxiliary measurement section are printed with a quick reference table for material layout 5. The main body surface is marked with a measuring scale 6 corresponding to each side of the auxiliary measurement section.

[0020] The measuring scale markings include imperial scale markings and at least one metric scale marking. Additionally, the measuring scale markings also include scale markings. Typically, the scale markings and imperial scale markings are located on the same side of the main body. By integrating imperial and metric scales and scale markings onto the main body, and placing the functionally related scale and imperial scales on the same side, the system achieves unified measurement across multiple systems and optimizes the operational process. This improves the adaptability and efficiency of on-site measurements. Construction personnel can directly handle drawings and physical measurements from different measurement systems without carrying multiple measuring tools, ensuring a smooth transition between operations such as reading drawings, conversions, and measurements, and avoiding unit conversion errors and wasted time switching tools.

[0021] The surface of the main body, differing from the imperial scale markings, features two sets of metric scale markings. These two sets of metric scales share the same origin and have overlapping zero lines. The presence of two sets of metric scales with overlapping zero lines and a shared origin on one side of the main body improves the accuracy and efficiency of complex layout operations. Construction personnel can precisely align the common origin with the pipeline baseline and directly perform bidirectional measurements or comparisons without moving tools, effectively avoiding the cumulative errors and operational inconvenience caused by repeated zeroing.

[0022] The reference lines include 0°, 15°, 30°, 45°, 60°, 75°, and 90° reference lines. This structural design ensures extremely high precision in the core area (the critical area for changes in the small-angle bend cutting line) while avoiding redundant scales. It achieves the best balance between the complexity of the tool structure and the completeness of its functions, enabling construction personnel to quickly and accurately locate all key points intersecting with the calculation radius R, thereby efficiently generating smooth and accurate horseshoe-shaped cutting lines.

[0023] The material cutting and layout quick reference tables include quick reference tables for laying out the 12 equal parts of the pipe circumference when the bending radius is 1 times the pipe diameter, quick reference tables for laying out the 12 equal parts of the pipe circumference when the bending radius is 1.5 times the pipe diameter, and quick reference tables for commonly used data. These quick reference tables cover pipe diameters from 600mm to 3200mm. By pre-setting the two most standard bending radius options for engineering projects, this tool can directly meet the requirements of most design specifications, avoiding complex radius conversions on-site. Covering the complete pipe diameter range from small to large diameters ensures its direct applicability in various pipeline engineering projects. Construction personnel do not need to consult cumbersome manuals or rely on error-prone memory; they can instantly obtain cutting data accurate to the millimeter simply by looking up tables and performing simple multiplication. This greatly improves the reliability, consistency, and efficiency of data acquisition, fundamentally eliminating the risk of batch quality accidents caused by parameter memory errors, inconvenient manual lookups, or temporary calculation errors, providing a solid guarantee for large-scale, high-quality on-site prefabrication.

[0024] This invention improves the accuracy and efficiency of on-site layout by integrating a sector layout module based on precise calculation data, a multi-functional quick reference table, and a measuring ruler. By replacing complex calculations and manual line drawing with a built-in quick reference table and data-driven layout, it fundamentally reduces cumulative errors and uneven joint gaps, enabling elbow fabrication to achieve a high-quality standard of "no-repair" or "minimal repair." It greatly enhances on-site adaptability. This layout device does not rely on external power supplies or CAD software, transforming operations that depend on personal experience into standardized processes that can be quickly trained. This effectively lowers the technical threshold for operators and reduces their dependence on specific tools, making it particularly suitable for rapid, high-precision construction in harsh conditions such as fieldwork and high-altitude environments.

[0025] The auxiliary measurement section has commonly used data and instructions for material cutting on the front and / or back, including but not limited to: Tangent data: tg1°=0.01746; tg2° = 0.01746 * 2 = 0.0349; tg3° = 0.01746 * 3 = 0.0524; The other angles are similar...

[0026] Calculation of maximum cutting surface: (External pipe wall cutting method) Maximum cutting surface = tg elbow angle * pipe outer diameter; (Pipe inner wall cutting method) Maximum cutting surface = tg elbow angle * pipe inner diameter.

[0027] Cutting ruler data description: The pipes used in this invention are typically standard steel pipes. Two sets of data are listed on the layout tool, covering pipe diameters from DN600 to DN3200, with radii of curvature of 1.0D and 1.5D respectively. When the outer diameter of the pipe deviates from the values ​​listed in the table within ±32mm, the values ​​can be directly taken from this table.

[0028] The following is a method for laying out small-angle elbows using the above-mentioned layout device, including the following steps: S1. Check the outer diameter of the pipe and calculate the maximum cutting surface. The maximum cutting surface A = tg elbow angle * pipe inner diameter. S2. Take the value of the layout, the layout value R = ½A; S3. Draw an arc with the vertex of the fan-shaped structure as the center and the lofting value R as the radius, and mark the intersection of the arc with each baseline. S4. Measure the vertical distance from each intersection point to the origin of the reference scale line; S5. Measure the circumference L of the inner wall of the pipe end; S6. Based on the circumference L, divide the pipe circumference into 24 equal parts. The axial length of each segment is taken as an integer that is close to and greater than the maximum cutting surface A. The segments at the four positions of "0 point", "3 point", "6 point" and "9 point" are lengthened to 1.5A and marked. S7. Mark the cutting points on the 24 lines along the circumference of the pipe, starting from "0 point", based on the values ​​measured in step S5. S8. Connect the cutting points to form a cutting line; S9. After cutting along the cutting line to form a horseshoe-shaped opening, connect the flush end of the pipe to the horseshoe-shaped opening to complete the elbow fabrication.

[0029] In an optional embodiment, taking the fabrication of a DN1000 (Φ1024*12mm)*5° elbow with a bending radius of 1.0D as an example, the specific steps are as follows: Step 1: Check the outer diameter of the pipe and calculate the maximum cutting surface (using the inner wall cutting method). According to the formula shown in the auxiliary measurement section: Maximum cutting surface A = tg elbow angle * pipe inner diameter = tg1°*5*1000=0.01746*5*1000=87.3mm According to the quick reference table of the 12 equal parts ½ pipe circumference layout method when the bending radius is 1 times the pipe diameter, the maximum allowable cutting size / angle limit of the horseshoe joint is 111mm / ≤6°. The maximum cutting size / angle of the horseshoe joint of the elbow to be made this time is 87.3mm / ≤5°, which is less than the requirement of 111mm / ≤6°. Therefore, it can be made by cutting on one side. Step 2: Determining the value of the layout value R R = ½A = 0.5 * 87.3 mm = 43.65 mm Step 3: As Figure 4 As shown, in the layout section, with the vertex of the fan-shaped structure as the center and a radius of 43.65mm, measure 43.65mm on the 15°, 30°, 45°, 60°, and 75° reference lines respectively, and mark the intersection points of the 43.65mm radius arc with each reference line. Step 4: As Figure 5 As shown, measure the perpendicular distance between each intersection point in the third step and the edge of the sector structure (i.e., the radius of the sector structure) (either direction is acceptable). Step 5: Measure the inner circumference (L) of the flush end of the DN1000 (Φ1024*12mm) pipe using a steel ruler: Example: The actual circumference of the inner wall of the flush end of a DN1000 (Φ1024*12mm) pipe is L=3142mm; Step 6: As Figure 6As shown, the center spacing R between the two connected DN1000 (Φ1024*12mm) pipes is determined. Based on the circumference L=3142mm measured in step 5, one of the pipe circumferences is divided into 24 parts. The axial length of each segment should be greater than the maximum cutting surface A (87.3mm), which is 90mm. The segments at the four positions of "0 point", "3 point", "6 point" and "9 point" are extended to 1.5A (about 130mm). Each point is marked with a stone pencil. Step 7: As Figure 7 As shown, measure 43.65mm dividing points along the 24 lines into the end of the DN1000 (Φ1024*12mm) pipe, and connect the dividing points with a steel ruler and a pencil to form dividing lines. Step 8: As Figure 8 As shown, the values ​​measured in the fourth step are marked on 12 lines 7 on each side of the tube, starting from "0 point", to form cutting points; Step 9: As Figure 9 As shown, use a steel ruler and a pencil to connect the cutting points to form a cutting line. That is, along the 12-part line direction, the distance between the cutting line and the dividing line are the values ​​measured in step four. The dimensions of each point on the cutting line are shown in the table below. Step 10: After cutting the pipe into a horseshoe shape along the cutting line, you will get... Figure 10 The cut shown is used to connect the flush end of a DN1000 (Φ1024*12mm) pipe to the horseshoe-shaped joint, thus completing the fabrication of the 5° elbow.

[0030] It should be noted that if a DN1000 (Φ1024*12mm) pipe 10° elbow needs to be fabricated on site, the size of the dividing line can be set according to the required size on site. The material cutting method is the same as described above. After cutting and grinding the interface, the "0 point" of one pipe section is connected to the "6 point" position of another pipe section to complete the on-site fabrication of the 10° elbow. The on-site fabrication of other large-angle elbows is the same as this example.

[0031] The layout tool provided by this invention includes a main body, which is divided into a layout section and an auxiliary measurement section. The layout section has a 90° sector-shaped structure, with reference scale lines and multiple reference lines with angle scales centered at the apex of the sector. The auxiliary measurement section has a quick reference table and commonly used data printed on both sides, covering pipe diameters of DN600-DN3200 and bending radii of 1.0D and 1.5D, for the 12-part ½-pipe circumference layout method. Each edge has imperial and metric scales and a scale. In application, the layout value R is determined by calculating the maximum cutting surface, and the layout tool is used to quickly obtain the cutting point data. Combined with the equal division of the pipe circumference, accurate marking is achieved. This invention integrates multiple functions, effectively solving the problems of large errors and low efficiency of traditional methods, significantly improving the accuracy and construction efficiency of on-site fabrication of small-angle elbows, reducing the end-cutting time, and is suitable for on-site elbow fabrication of steel pipes.

[0032] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A small-angle elbow feeding and distribution device, characterized in that, The device includes a main body, which comprises a layout section and an auxiliary measurement section. The layout section is printed with reference scale lines and has several reference lines with angle scales on a fan-shaped structure. The front and back of the auxiliary measurement section are printed with a quick reference table for material layout. Corresponding to each side of the auxiliary measurement section, the main body surface is marked with measuring scale marks, including imperial scale marks and at least one metric scale mark.

2. The small-angle elbow feeding and layout device according to claim 1, characterized in that: The measuring scale markings also include scale markings.

3. The small-angle elbow feeding and layout device according to claim 2, characterized in that: The scale markings and imperial scale markings are located on the same side surface of the body.

4. The small-angle elbow feeding and layout device according to claim 2, characterized in that: The surface of the main body, which is different from the imperial scale markings, has two sets of metric scale markings. The zero lines of these two sets of metric scales coincide and share the same origin.

5. A small-angle elbow feeding and layout device according to claim 1, characterized in that: The baselines include 0° baseline, 15° baseline, 30° baseline, 45° baseline, 60° baseline, 75° baseline and 90° baseline.

6. The small-angle elbow feeding and layout device according to claim 1, characterized in that: The quick reference tables for material layout include quick reference tables for laying out the 12 equal parts of the pipe circumference when the bending radius is 1 times the pipe diameter, quick reference tables for laying out the 12 equal parts of the pipe circumference when the bending radius is 1.5 times the pipe diameter, and quick reference tables for commonly used data.

7. A small-angle elbow feeding and layout device according to claim 1, characterized in that: The quick reference table for material layout covers pipe diameters ranging from 600mm to 3200mm.

8. A method for laying out small-angle bends using the lofting device according to any one of claims 1 to 7, characterized in that, Includes the following steps: S1. Check the outer diameter of the pipe and calculate the maximum cutting surface. The maximum cutting surface A = tg elbow angle * pipe inner diameter. S2. Take the value of the layout, the layout value R = ½A; S3. Draw an arc with the vertex of the fan-shaped structure as the center and the lofting value R as the radius, and mark the intersection of the arc with each baseline. S4. Measure the vertical distance from each intersection point to the origin of the reference scale line; S5. Measure the circumference L of the inner wall of the pipe end; S6. Based on the circumference L, divide the pipe circumference into 24 equal parts. The axial length of each segment is taken as an integer that is close to and greater than the maximum cutting surface A. The segments at the four positions of "0 point", "3 point", "6 point" and "9 point" are lengthened to 1.5A and marked. S7. Mark the cutting points on the 24 lines along the circumference of the pipe, starting from "0 point", based on the values ​​measured in step S5. S8. Connect the cutting points to form a cutting line; S9. After cutting along the cutting line to form a horseshoe-shaped opening, connect the flush end of the pipe to the horseshoe-shaped opening to complete the elbow fabrication.

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